Surgical anvil arrangements

ABSTRACT

A surgical stapling anvil is disclosed comprising an anvil body including a tissue-facing surface, a plurality of staple forming pockets, and a longitudinal slot. The longitudinal slot comprises a first portion configured to receive a cutting edge of a firing member therethrough and a second portion configured to receive an anvil-camming portion of the firing member therethrough. The anvil further comprises an anvil cap welded to the anvil body, wherein the anvil cap comprises a welded portion and a non-welded portion, wherein the non-welded portion comprises a non-welded width, and wherein the non-welded width is less than or equal to about 105% of the width of the second portion.

BACKGROUND

The present invention relates to surgical instruments and, in variousarrangements, to surgical stapling and cutting instruments and staplecartridges for use therewith that are designed to staple and cut tissue.

BRIEF DESCRIPTION OF THE DRAWINGS

Various features of the embodiments described herein, together withadvantages thereof, may be understood in accordance with the followingdescription taken in conjunction with the accompanying drawings asfollows:

FIG. 1 is a side elevational view of a surgical system comprising ahandle assembly and multiple interchangeable surgical tool assembliesthat may be used therewith;

FIG. 2 is a perspective view of one of the interchangeable surgical toolassemblies of FIG. 1 operably coupled to the handle assembly of FIG. 1;

FIG. 3 is an exploded assembly view of portions of the handle assemblyand interchangeable surgical tool assembly of FIGS. 1 and 2;

FIG. 4 is a perspective view of another one of the interchangeablesurgical tool assemblies depicted in FIG. 1;

FIG. 5 is a partial cross-sectional perspective view of theinterchangeable surgical tool assembly of FIG. 4;

FIG. 6 is another partial cross-sectional view of a portion of theinterchangeable surgical tool assembly of FIGS. 4 and 5;

FIG. 7 is an exploded assembly view of a portion of the interchangeablesurgical tool assembly of FIGS. 4-6;

FIG. 7A is an enlarged top view of a portion of an elastic spineassembly of the interchangeable surgical tool assembly of FIG. 7;

FIG. 8 is an exploded assembly view of a portion of the interchangeablesurgical tool assembly of FIGS. 4-7;

FIG. 9 is a cross-sectional perspective view of a surgical end effectorportion of the interchangeable surgical tool assembly of FIGS. 4-8;

FIG. 10 is an exploded assembly view of the surgical end effectorportion of the interchangeable surgical tool assembly depicted in FIG.9;

FIG. 11 is a perspective view, a side elevational view and a frontelevational view of a firing member that may be employed in theinterchangeable surgical tool assembly of FIGS. 4-10;

FIG. 12 is a perspective view of an anvil that may be employed in theinterchangeable surgical tool assembly of FIGS. 4-11;

FIG. 13 is a cross-sectional side elevational view of the anvil of FIG.12;

FIG. 14 is a bottom view of the anvil of FIGS. 12 and 13;

FIG. 15 is a cross-sectional side elevational view of a portion of asurgical end effector and shaft portion of the interchangeable surgicaltool assembly of FIG. 4 with an unspent surgical staple cartridgeproperly seated within an elongate channel of the surgical end effector;

FIG. 16 is a cross-sectional side elevational view of the surgical endeffector and shaft portion of FIG. 15 after the surgical staplecartridge has been fired during a staple firing stroke and a firingmember being retracted to a starting position after the staple firingstroke;

FIG. 17 is another cross-sectional side elevational view of the surgicalend effector and shaft portion of FIG. 16 after the firing member hasbeen fully retracted back to its starting position;

FIG. 18 is a top cross-sectional view of the surgical end effector andshaft portion depicted in FIG. 15 with the unspent surgical staplecartridge properly seated with the elongate channel of the surgical endeffector;

FIG. 19 is another top cross-sectional view of the surgical end effectorof FIG. 15 with a fired surgical staple cartridge mounted thereinillustrating the firing member retained in a locked position;

FIG. 20 is a partial cross-sectional view of portions of the anvil andelongate channel of the interchangeable tool assembly of FIG. 4;

FIG. 21 is an exploded side elevational view of portions of the anviland elongate channel of FIG. 20;

FIG. 22 is a rear perspective view of an anvil mounting portion of ananvil in accordance with at least one embodiment;

FIG. 23 is a rear perspective view of an anvil mounting portion ofanother anvil in accordance with at least one embodiment;

FIG. 24 is a rear perspective view of an anvil mounting portion ofanother anvil in accordance with at least one embodiment;

FIG. 25 is a perspective view of an anvil in accordance with at leastone embodiment;

FIG. 26 is an exploded perspective view of the anvil of FIG. 25;

FIG. 27 is a cross-sectional end view of the anvil of FIG. 25;

FIG. 28 is a perspective view of another anvil in accordance with atleast one embodiment;

FIG. 29 is an exploded perspective view of the anvil embodiment of FIG.28;

FIG. 30 is a top view of a distal end portion of an anvil body portionof the anvil of FIG. 28;

FIG. 31 is a top view of a distal end portion of an anvil body portionof another anvil in accordance with at least one embodiment;

FIG. 32 is a cross-sectional end perspective view of the anvil of FIG.31;

FIG. 33 is a cross-sectional end perspective view of another anvil inaccordance with at least one embodiment;

FIG. 34 provides a comparison between a first embodiment of an anvil anda second embodiment of an anvil;

FIG. 35 is a cross-sectional view of an end effector comprising thesecond anvil embodiment of FIG. 34;

FIG. 36 is a partial cross-sectional view of the first anvil embodimentof FIG. 34 and a firing member configured to engage the first anvilembodiment;

FIG. 37 is a partial elevational view of the firing member of FIG. 36;

FIG. 38 is an illustration depicting stress concentrations in the firstanvil embodiment of FIG. 34 and the firing member of FIG. 36;

FIG. 39 is an another illustration depicting stress concentrations inthe firing member of FIG. 36;

FIG. 40 is a perspective view of a firing member in accordance with atleast one embodiment;

FIG. 41 is a side elevational view of the firing member of FIG. 40;

FIG. 42 is a front elevational view of the firing member of FIG. 40;

FIG. 43 is a partial perspective view of a firing member in accordancewith at least one embodiment;

FIG. 44 is a partial side elevational view of the firing member of FIG.43;

FIG. 45 is a partial front elevational view of the firing member of FIG.43;

FIG. 46 is a partial perspective view of a firing member in accordancewith at least one embodiment;

FIG. 47 is a partial side elevational view of the firing member of FIG.46;

FIG. 48 is a partial front elevational view of the firing member of FIG.46;

FIG. 49 is a partial perspective view of a firing member in accordancewith at least one embodiment;

FIG. 50 is a partial side elevational view of the firing member of FIG.49;

FIG. 51 is a partial front elevational view of the firing member of FIG.49;

FIG. 52 is a partial perspective view of a firing member in accordancewith at least one embodiment;

FIG. 53 is a partial side elevational view of the firing member of FIG.52;

FIG. 54 is a partial front elevational view of the firing member of FIG.52;

FIG. 55 is a partial perspective view of a firing member in accordancewith at least one embodiment;

FIG. 56 is a partial side elevational view of the firing member of FIG.55;

FIG. 57 is a partial front elevational view of the firing member of FIG.55;

FIG. 58 is a partial perspective view of a firing member in accordancewith at least one embodiment;

FIG. 59 is a partial side elevational view of the firing member of FIG.58;

FIG. 60 is a partial front elevational view of the firing member of FIG.58;

FIG. 61 is a partial perspective view of a firing member in accordancewith at least one embodiment;

FIG. 62 is a partial side elevational view of the firing member of FIG.61;

FIG. 63 is a partial front elevational view of the firing member of FIG.61;

FIG. 64 is a partial perspective view of a firing member in accordancewith at least one embodiment;

FIG. 65 is a partial side elevational view of the firing member of FIG.64;

FIG. 66 is another partial perspective view of the firing member of FIG.64;

FIG. 67 is a partial front elevational view of the firing member of FIG.64;

FIG. 68 is a schematic depicting the energy needed to advance firingmembers disclosed herein through staple firing strokes;

FIG. 69 is a detail view of a lateral projection extending from thefiring member of FIG. 43 schematically illustrating the interactionbetween the lateral projection and an anvil in a flexed condition;

FIG. 70 is a detail view of a lateral projection extending from thefiring member of FIG. 58 schematically illustrating the interactionbetween the lateral projection and an anvil in a flexed condition;

FIG. 71 is a detail view of a lateral projection extending from thefiring member of FIG. 58 schematically illustrating the interactionbetween the lateral projection and an anvil another flexed condition;

FIG. 72 is a perspective view of an anvil of a surgical staplinginstrument comprising an anvil body and an anvil cap;

FIG. 73 is an exploded view of the anvil of FIG. 72;

FIG. 74 is a partial, cross-sectional view of a welded, anvil comprisingvertical welding surfaces;

FIG. 75 is a partial, cross-sectional view of a welded, anvil comprisinghorizontal welding surfaces;

FIG. 76 is a partial, cross-sectional view of a welded, anvil comprisingangular welding surfaces;

FIG. 77 is a cross-sectional view an anvil comprising an anvil body andan anvil cap, wherein the anvil body and the anvil cap are welded toeach other;

FIG. 78 is a micrograph of a surgical stapling anvil comprising a firstanvil member and a second anvil member, wherein the first anvil memberand the second anvil member are welded to each other;

FIG. 79 is a cross-sectional view of a surgical stapling anvilcomprising an anvil body and an anvil cap;

FIG. 80 is a chart representing four different surgical stapling anvilarrangements subject to two different load scenarios comprisingdeflection and stress data for a first scenario and stress data for asecond scenario;

FIG. 81 is a perspective view of an anvil comprising a first anvilmember and a second anvil member, wherein the anvil members comprise aweld configuration configured to increase overall weld depth;

FIG. 82 is a cross-sectional view of the surgical stapling anvil of FIG.81 prior to welding taken along line 82-82 in FIG. 81;

FIG. 83 is a cross-sectional view of the surgical stapling anvil of FIG.81 after welding taken along line 83-83 in FIG. 81;

FIG. 84 is a cross-sectional view of a surgical stapling anvilcomprising a first anvil member and a second anvil member welded to eachother;

FIG. 85 is a partial cross-sectional, partially exploded view of thesurgical stapling anvil of FIG. 84;

FIG. 86 is a cross-sectional view of a surgical stapling anvilcomprising a first anvil member and a second anvil member welded to eachother, wherein the anvil members comprise interlocking features;

FIG. 87 is a cross-sectional view of a surgical stapling anvilcomprising a first anvil member and a second anvil member welded to eachother, wherein the anvil members comprise interlocking features;

FIG. 88 is a perspective view of an end effector assembly illustrated inan open configuration;

FIG. 89 is a perspective view of the end effector assembly of FIG. 88illustrated in a closed configuration;

FIG. 90 is a partial cross-sectional view of the end effector assemblyof FIG. 88 taken along line 90-90 in FIG. 88;

FIG. 91 is a partial cross-sectional view of the end effector assemblyof FIG. 88 taken along line 91-91 in FIG. 89;

FIG. 92 is a cross-sectional view of the end effector assembly of FIG.88 taken along line 92-92 in FIG. 89;

FIG. 93 is a perspective view of a staple cartridge channel comprising achannel body and a channel cap welded thereto;

FIG. 94 is an exploded view of the staple cartridge channel of FIG. 93;

FIG. 95 is a cross-sectional view of a staple cartridge channelcomprising a first channel member and a second channel member welded toeach other;

FIG. 96 is a perspective view of a firing member for use with a surgicalinstrument, wherein the firing member comprises a first jaw-couplingmember and a second jaw-coupling member;

FIG. 97 is a perspective view of another firing member for use with asurgical instrument, wherein the firing member comprises a firstjaw-coupling member and a second jaw-coupling member;

FIG. 98 is a front view of the firing member of FIG. 96;

FIG. 99 is an elevational view of the firing member of FIG. 96;

FIG. 100 is a front view of the firing member of FIG. 97;

FIG. 101 is an elevational view of the firing member of FIG. 97;

FIG. 102 is a partial elevational view of the firing member of FIG. 96;

FIG. 103 is a partial elevational view of the firing member of FIG. 97;

FIG. 104 is a cross-sectional view of a stapling system comprising thefiring member of FIG. 97;

FIG. 105 is a cross-sectional view of a stapling system comprising thefiring member of FIG. 96;

FIG. 106 is a partial cross-sectional view of an anvil and the firingmember of the stapling system of FIG. 105;

FIG. 107 is a partial cross-sectional view of an anvil and the firingmember of the stapling system of FIG. 104; and

FIG. 108 is a stress analysis of the anvil of the stapling system ofFIG. 105.

Corresponding reference characters indicate corresponding partsthroughout the several views. The exemplifications set out hereinillustrate various embodiments of the invention, in one form, and suchexemplifications are not to be construed as limiting the scope of theinvention in any manner.

DETAILED DESCRIPTION

Applicant of the present application owns the following U.S. PatentApplications that were filed on Jun. 27, 2017 and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 15/634,024, entitled SURGICAL        ANVIL MANUFACTURING METHODS, now U.S. Patent Application        Publication No. 2018/0368839;    -   U.S. patent application Ser. No. 15/634,035, entitled SURGICAL        ANVIL ARRANGEMENTS, now U.S. Patent Application Publication No.        2018/0368840;    -   U.S. patent application Ser. No. 15/634,054, entitled SURGICAL        ANVIL ARRANGEMENTS, now U.S. Patent Application Publication No.        2018/0368842;    -   U.S. patent application Ser. No. 15/634,068, entitled SURGICAL        FIRING MEMBER ARRANGEMENTS, now U.S. Patent Application        Publication No. 2018/0368843;    -   U.S. patent application Ser. No. 15/634,076, entitled STAPLE        FORMING POCKET ARRANGEMENTS, now U.S. Patent Application        Publication No. 2018/0368844;    -   U.S. patent application Ser. No. 15/634,090, entitled STAPLE        FORMING POCKET ARRANGEMENTS, now U.S. Patent Application        Publication No. 2018/0368845;    -   U.S. patent application Ser. No. 15/634,099, entitled SURGICAL        END EFFECTORS AND ANVILS, now U.S. Patent Application        Publication No. 2018/0368846;    -   U.S. patent application Ser. No. 15/634,117, entitled        ARTICULATION SYSTEMS FOR SURGICAL INSTRUMENTS, now U.S. Patent        Application Publication No. 2018/0368847;

Applicant of the present application owns the following U.S. PatentApplications that were filed on Dec. 21, 2016 and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 15/386,185, entitled SURGICAL        STAPLING INSTRUMENTS AND REPLACEABLE TOOL ASSEMBLIES THEREOF;    -   U.S. patent application Ser. No. 15/386,230, entitled        ARTICULATABLE SURGICAL STAPLING INSTRUMENTS;    -   U.S. patent application Ser. No. 15/386,221, entitled LOCKOUT        ARRANGEMENTS FOR SURGICAL END EFFECTORS;    -   U.S. patent application Ser. No. 15/386,209, entitled SURGICAL        END EFFECTORS AND FIRING MEMBERS THEREOF;    -   U.S. patent application Ser. No. 15/386,198, entitled LOCKOUT        ARRANGEMENTS FOR SURGICAL END EFFECTORS AND REPLACEABLE TOOL        ASSEMBLIES;    -   U.S. patent application Ser. No. 15/386,240, entitled SURGICAL        END EFFECTORS AND ADAPTABLE FIRING MEMBERS THEREFOR;    -   U.S. patent application Ser. No. 15/385,939, entitled STAPLE        CARTRIDGES AND ARRANGEMENTS OF STAPLES AND STAPLE CAVITIES        THEREIN;    -   U.S. patent application Ser. No. 15/385,941, entitled SURGICAL        TOOL ASSEMBLIES WITH CLUTCHING ARRANGEMENTS FOR SHIFTING BETWEEN        CLOSURE SYSTEMS WITH CLOSURE STROKE REDUCTION FEATURES AND        ARTICULATION AND FIRING SYSTEMS;    -   U.S. patent application Ser. No. 15/385,943, entitled SURGICAL        STAPLING INSTRUMENTS AND STAPLE-FORMING ANVILS;    -   U.S. patent application Ser. No. 15/385,950, entitled SURGICAL        TOOL ASSEMBLIES WITH CLOSURE STROKE REDUCTION FEATURES;    -   U.S. patent application Ser. No. 15/385,945, entitled STAPLE        CARTRIDGES AND ARRANGEMENTS OF STAPLES AND STAPLE CAVITIES        THEREIN;    -   U.S. patent application Ser. No. 15/385,946, entitled SURGICAL        STAPLING INSTRUMENTS AND STAPLE-FORMING ANVILS;    -   U.S. patent application Ser. No. 15/385,951, entitled SURGICAL        INSTRUMENTS WITH JAW OPENING FEATURES FOR INCREASING A JAW        OPENING DISTANCE;    -   U.S. patent application Ser. No. 15/385,953, entitled METHODS OF        STAPLING TISSUE;    -   U.S. patent application Ser. No. 15/385,954, entitled FIRING        MEMBERS WITH NON-PARALLEL JAW ENGAGEMENT FEATURES FOR SURGICAL        END EFFECTORS;    -   U.S. patent application Ser. No. 15/385,955, entitled SURGICAL        END EFFECTORS WITH EXPANDABLE TISSUE STOP ARRANGEMENTS;    -   U.S. patent application Ser. No. 15/385,948, entitled SURGICAL        STAPLING INSTRUMENTS AND STAPLE-FORMING ANVILS;    -   U.S. patent application Ser. No. 15/385,956, entitled SURGICAL        INSTRUMENTS WITH POSITIVE JAW OPENING FEATURES;    -   U.S. patent application Ser. No. 15/385,958, entitled SURGICAL        INSTRUMENTS WITH LOCKOUT ARRANGEMENTS FOR PREVENTING FIRING        SYSTEM ACTUATION UNLESS AN UNSPENT STAPLE CARTRIDGE IS PRESENT;    -   U.S. patent application Ser. No. 15/385,947, entitled STAPLE        CARTRIDGES AND ARRANGEMENTS OF STAPLES AND STAPLE CAVITIES        THEREIN;    -   U.S. patent application Ser. No. 15/385,896, entitled METHOD FOR        RESETTING A FUSE OF A SURGICAL INSTRUMENT SHAFT;    -   U.S. patent application Ser. No. 15/385,898, entitled STAPLE        FORMING POCKET ARRANGEMENT TO ACCOMMODATE DIFFERENT TYPES OF        STAPLES;    -   U.S. patent application Ser. No. 15/385,899, entitled SURGICAL        INSTRUMENT COMPRISING IMPROVED JAW CONTROL;    -   U.S. patent application Ser. No. 15/385,901, entitled STAPLE        CARTRIDGE AND STAPLE CARTRIDGE CHANNEL COMPRISING WINDOWS        DEFINED THEREIN;    -   U.S. patent application Ser. No. 15/385,902, entitled SURGICAL        INSTRUMENT COMPRISING A CUTTING MEMBER;    -   U.S. patent application Ser. No. 15/385,904, entitled STAPLE        FIRING MEMBER COMPRISING A MISSING CARTRIDGE AND/OR SPENT        CARTRIDGE LOCKOUT;    -   U.S. patent application Ser. No. 15/385,905, entitled FIRING        ASSEMBLY COMPRISING A LOCKOUT;    -   U.S. patent application Ser. No. 15/385,907, entitled SURGICAL        INSTRUMENT SYSTEM COMPRISING AN END EFFECTOR LOCKOUT AND A        FIRING ASSEMBLY LOCKOUT;    -   U.S. patent application Ser. No. 15/385,908, entitled FIRING        ASSEMBLY COMPRISING A FUSE;    -   U.S. patent application Ser. No. 15/385,909, entitled FIRING        ASSEMBLY COMPRISING A MULTIPLE FAILED-STATE FUSE;    -   U.S. patent application Ser. No. 15/385,920, entitled STAPLE        FORMING POCKET ARRANGEMENTS;    -   U.S. patent application Ser. No. 15/385,913, entitled ANVIL        ARRANGEMENTS FOR SURGICAL STAPLE/FASTENERS;    -   U.S. patent application Ser. No. 15/385,914, entitled METHOD OF        DEFORMING STAPLES FROM TWO DIFFERENT TYPES OF STAPLE CARTRIDGES        WITH THE SAME SURGICAL STAPLING INSTRUMENT;    -   U.S. patent application Ser. No. 15/385,893, entitled        BILATERALLY ASYMMETRIC STAPLE FORMING POCKET PAIRS;    -   U.S. patent application Ser. No. 15/385,929, entitled CLOSURE        MEMBERS WITH CAM SURFACE ARRANGEMENTS FOR SURGICAL INSTRUMENTS        WITH SEPARATE AND DISTINCT CLOSURE AND FIRING SYSTEMS;    -   U.S. patent application Ser. No. 15/385,911, entitled SURGICAL        STAPLE/FASTENERS WITH INDEPENDENTLY ACTUATABLE CLOSING AND        FIRING SYSTEMS;    -   U.S. patent application Ser. No. 15/385,927, entitled SURGICAL        STAPLING INSTRUMENTS WITH SMART STAPLE CARTRIDGES;    -   U.S. patent application Ser. No. 15/385,917, entitled STAPLE        CARTRIDGE COMPRISING STAPLES WITH DIFFERENT CLAMPING BREADTHS;    -   U.S. patent application Ser. No. 15/385,900, entitled STAPLE        FORMING POCKET ARRANGEMENTS COMPRISING PRIMARY SIDEWALLS AND        POCKET SIDEWALLS;    -   U.S. patent application Ser. No. 15/385,931, entitled        NO-CARTRIDGE AND SPENT CARTRIDGE LOCKOUT ARRANGEMENTS FOR        SURGICAL STAPLE/FASTENERS;    -   U.S. patent application Ser. No. 15/385,915, entitled FIRING        MEMBER PIN ANGLE;    -   U.S. patent application Ser. No. 15/385,897, entitled STAPLE        FORMING POCKET ARRANGEMENTS COMPRISING ZONED FORMING SURFACE        GROOVES;    -   U.S. patent application Ser. No. 15/385,922, entitled SURGICAL        INSTRUMENT WITH MULTIPLE FAILURE RESPONSE MODES;    -   U.S. patent application Ser. No. 15/385,924, entitled SURGICAL        INSTRUMENT WITH PRIMARY AND SAFETY PROCESSORS;    -   U.S. patent application Ser. No. 15/385,912, entitled SURGICAL        INSTRUMENTS WITH JAWS THAT ARE PIVOTABLE ABOUT A FIXED AXIS AND        INCLUDE SEPARATE AND DISTINCT CLOSURE AND FIRING SYSTEMS;    -   U.S. patent application Ser. No. 15/385,910, entitled ANVIL        HAVING A KNIFE SLOT WIDTH;    -   U.S. patent application Ser. No. 15/385,906, entitled FIRING        MEMBER PIN CONFIGURATIONS;    -   U.S. patent application Ser. No. 15/386,188, entitled STEPPED        STAPLE CARTRIDGE WITH ASYMMETRICAL STAPLES;    -   U.S. patent application Ser. No. 15/386,192, entitled STEPPED        STAPLE CARTRIDGE WITH TISSUE RETENTION AND GAP SETTING FEATURES;    -   U.S. patent application Ser. No. 15/386,206, entitled STAPLE        CARTRIDGE WITH DEFORMABLE DRIVER RETENTION FEATURES;    -   U.S. patent application Ser. No. 15/386,226, entitled DURABILITY        FEATURES FOR END EFFECTORS AND FIRING ASSEMBLIES OF SURGICAL        STAPLING INSTRUMENTS;    -   U.S. patent application Ser. No. 15/386,222, entitled SURGICAL        STAPLING INSTRUMENTS HAVING END EFFECTORS WITH POSITIVE OPENING        FEATURES;    -   U.S. patent application Ser. No. 15/386,236, entitled CONNECTION        PORTIONS FOR DEPOSABLE LOADING UNITS FOR SURGICAL STAPLING        INSTRUMENTS;    -   U.S. patent application Ser. No. 15/385,887, entitled METHOD FOR        ATTACHING A SHAFT ASSEMBLY TO A SURGICAL INSTRUMENT AND,        ALTERNATIVELY, TO A SURGICAL ROBOT;    -   U.S. patent application Ser. No. 15/385,889, entitled SHAFT        ASSEMBLY COMPRISING A MANUALLY-OPERABLE RETRACTION SYSTEM FOR        USE WITH A MOTORIZED SURGICAL INSTRUMENT SYSTEM;    -   U.S. patent application Ser. No. 15/385,890, entitled SHAFT        ASSEMBLY COMPRISING SEPARATELY ACTUATABLE AND RETRACTABLE        SYSTEMS;    -   U.S. patent application Ser. No. 15/385,891, entitled SHAFT        ASSEMBLY COMPRISING A CLUTCH CONFIGURED TO ADAPT THE OUTPUT OF A        ROTARY FIRING MEMBER TO TWO DIFFERENT SYSTEMS;    -   U.S. patent application Ser. No. 15/385,892, entitled SURGICAL        SYSTEM COMPRISING A FIRING MEMBER ROTATABLE INTO AN ARTICULATION        STATE TO ARTICULATE AN END EFFECTOR OF THE SURGICAL SYSTEM;    -   U.S. patent application Ser. No. 15/385,894, entitled SHAFT        ASSEMBLY COMPRISING A LOCKOUT;    -   U.S. patent application Ser. No. 15/385,895, entitled SHAFT        ASSEMBLY COMPRISING FIRST AND SECOND ARTICULATION LOCKOUTS;    -   U.S. patent application Ser. No. 15/385,916, entitled SURGICAL        STAPLING SYSTEMS;    -   U.S. patent application Ser. No. 15/385,918, entitled SURGICAL        STAPLING SYSTEMS;    -   U.S. patent application Ser. No. 15/385,919, entitled SURGICAL        STAPLING SYSTEMS;    -   U.S. patent application Ser. No. 15/385,921, entitled SURGICAL        STAPLE/FASTENER CARTRIDGE WITH MOVABLE CAMMING MEMBER CONFIGURED        TO DISENGAGE FIRING MEMBER LOCKOUT FEATURES;    -   U.S. patent application Ser. No. 15/385,923, entitled SURGICAL        STAPLING SYSTEMS;    -   U.S. patent application Ser. No. 15/385,925, entitled JAW        ACTUATED LOCK ARRANGEMENTS FOR PREVENTING ADVANCEMENT OF A        FIRING MEMBER IN A SURGICAL END EFFECTOR UNLESS AN UNFIRED        CARTRIDGE IS INSTALLED IN THE END EFFECTOR;    -   U.S. patent application Ser. No. 15/385,926, entitled AXIALLY        MOVABLE CLOSURE SYSTEM ARRANGEMENTS FOR APPLYING CLOSURE MOTIONS        TO JAWS OF SURGICAL INSTRUMENTS;    -   U.S. patent application Ser. No. 15/385,928, entitled PROTECTIVE        COVER ARRANGEMENTS FOR A JOINT INTERFACE BETWEEN A MOVABLE JAW        AND ACTUATOR SHAFT OF A SURGICAL INSTRUMENT;    -   U.S. patent application Ser. No. 15/385,930, entitled SURGICAL        END EFFECTOR WITH TWO SEPARATE COOPERATING OPENING FEATURES FOR        OPENING AND CLOSING END EFFECTOR JAWS;    -   U.S. patent application Ser. No. 15/385,932, entitled        ARTICULATABLE SURGICAL END EFFECTOR WITH ASYMMETRIC SHAFT        ARRANGEMENT;    -   U.S. patent application Ser. No. 15/385,933, entitled        ARTICULATABLE SURGICAL INSTRUMENT WITH INDEPENDENT PIVOTABLE        LINKAGE DISTAL OF AN ARTICULATION LOCK;    -   U.S. patent application Ser. No. 15/385,934, entitled        ARTICULATION LOCK ARRANGEMENTS FOR LOCKING AN END EFFECTOR IN AN        ARTICULATED POSITION IN RESPONSE TO ACTUATION OF A JAW CLOSURE        SYSTEM;    -   U.S. patent application Ser. No. 15/385,935, entitled LATERALLY        ACTUATABLE ARTICULATION LOCK ARRANGEMENTS FOR LOCKING AN END        EFFECTOR OF A SURGICAL INSTRUMENT IN AN ARTICULATED        CONFIGURATION; and    -   U.S. patent application Ser. No. 15/385,936, entitled        ARTICULATABLE SURGICAL INSTRUMENTS WITH ARTICULATION STROKE        AMPLIFICATION FEATURES.

Applicant of the present application owns the following U.S. PatentApplications that were filed on Jun. 24, 2016 and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 15/191,775, entitled STAPLE        CARTRIDGE COMPRISING WIRE STAPLES AND STAMPED STAPLES;    -   U.S. patent application Ser. No. 15/191,807, entitled STAPLING        SYSTEM FOR USE WITH WIRE STAPLES AND STAMPED STAPLES;    -   U.S. patent application Ser. No. 15/191,834, entitled STAMPED        STAPLES AND STAPLE CARTRIDGES USING THE SAME;    -   U.S. patent application Ser. No. 15/191,788, entitled STAPLE        CARTRIDGE COMPRISING OVERDRIVEN STAPLES; and    -   U.S. patent application Ser. No. 15/191,818, entitled STAPLE        CARTRIDGE COMPRISING OFFSET LONGITUDINAL STAPLE ROWS.

Applicant of the present application owns the following U.S. PatentApplications that were filed on Jun. 24, 2016 and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. Design patent application Ser. No. 29/569,218, entitled        SURGICAL FASTENER;    -   U.S. Design patent application Ser. No. 29/569,227, entitled        SURGICAL FASTENER;    -   U.S. Design patent application Ser. No. 29/569,259, entitled        SURGICAL FASTENER CARTRIDGE; and    -   U.S. Design patent application Ser. No. 29/569,264, entitled        SURGICAL FASTENER CARTRIDGE.

Applicant of the present application owns the following patentapplications that were filed on Apr. 1, 2016 and which are each hereinincorporated by reference in their respective entirety:

-   -   U.S. patent application Ser. No. 15/089,325, entitled METHOD FOR        OPERATING A SURGICAL STAPLING SYSTEM;    -   U.S. patent application Ser. No. 15/089,321, entitled MODULAR        SURGICAL STAPLING SYSTEM COMPRISING A DISPLAY;    -   U.S. patent application Ser. No. 15/089,326, entitled SURGICAL        STAPLING SYSTEM COMPRISING A DISPLAY INCLUDING A RE-ORIENTABLE        DISPLAY FIELD;    -   U.S. patent application Ser. No. 15/089,263, entitled SURGICAL        INSTRUMENT HANDLE ASSEMBLY WITH RECONFIGURABLE GRIP PORTION;    -   U.S. patent application Ser. No. 15/089,262, entitled ROTARY        POWERED SURGICAL INSTRUMENT WITH MANUALLY ACTUATABLE BAILOUT        SYSTEM;    -   U.S. patent application Ser. No. 15/089,277, entitled SURGICAL        CUTTING AND STAPLING END EFFECTOR WITH ANVIL CONCENTRIC DRIVE        MEMBER;    -   U.S. patent application Ser. No. 15/089,296, entitled        INTERCHANGEABLE SURGICAL TOOL ASSEMBLY WITH A SURGICAL END        EFFECTOR THAT IS SELECTIVELY ROTATABLE ABOUT A SHAFT AXIS;    -   U.S. patent application Ser. No. 15/089,258, entitled SURGICAL        STAPLING SYSTEM COMPRISING A SHIFTABLE TRANSMISSION;    -   U.S. patent application Ser. No. 15/089,278, entitled SURGICAL        STAPLING SYSTEM CONFIGURED TO PROVIDE SELECTIVE CUTTING OF        TISSUE;    -   U.S. patent application Ser. No. 15/089,284, entitled SURGICAL        STAPLING SYSTEM COMPRISING A CONTOURABLE SHAFT;    -   U.S. patent application Ser. No. 15/089,295, entitled SURGICAL        STAPLING SYSTEM COMPRISING A TISSUE COMPRESSION LOCKOUT;    -   U.S. patent application Ser. No. 15/089,300, entitled SURGICAL        STAPLING SYSTEM COMPRISING AN UNCLAMPING LOCKOUT;    -   U.S. patent application Ser. No. 15/089,196, entitled SURGICAL        STAPLING SYSTEM COMPRISING A JAW CLOSURE LOCKOUT;    -   U.S. patent application Ser. No. 15/089,203, entitled SURGICAL        STAPLING SYSTEM COMPRISING A JAW ATTACHMENT LOCKOUT;    -   U.S. patent application Ser. No. 15/089,210, entitled SURGICAL        STAPLING SYSTEM COMPRISING A SPENT CARTRIDGE LOCKOUT;    -   U.S. patent application Ser. No. 15/089,324, entitled SURGICAL        INSTRUMENT COMPRISING A SHIFTING MECHANISM;    -   U.S. patent application Ser. No. 15/089,335, entitled SURGICAL        STAPLING INSTRUMENT COMPRISING MULTIPLE LOCKOUTS;    -   U.S. patent application Ser. No. 15/089,339, entitled SURGICAL        STAPLING INSTRUMENT;    -   U.S. patent application Ser. No. 15/089,253, entitled SURGICAL        STAPLING SYSTEM CONFIGURED TO APPLY ANNULAR ROWS OF STAPLES        HAVING DIFFERENT HEIGHTS;    -   U.S. patent application Ser. No. 15/089,304, entitled SURGICAL        STAPLING SYSTEM COMPRISING A GROOVED FORMING POCKET;    -   U.S. patent application Ser. No. 15/089,331, entitled ANVIL        MODIFICATION MEMBERS FOR SURGICAL STAPLE/FASTENERS;    -   U.S. patent application Ser. No. 15/089,336, entitled STAPLE        CARTRIDGES WITH ATRAUMATIC FEATURES;    -   U.S. patent application Ser. No. 15/089,312, entitled CIRCULAR        STAPLING SYSTEM COMPRISING AN INCISABLE TISSUE SUPPORT;    -   U.S. patent application Ser. No. 15/089,309, entitled CIRCULAR        STAPLING SYSTEM COMPRISING ROTARY FIRING SYSTEM; and    -   U.S. patent application Ser. No. 15/089,349, entitled CIRCULAR        STAPLING SYSTEM COMPRISING LOAD CONTROL.

Applicant of the present application also owns the U.S. PatentApplications identified below which were filed on Dec. 31, 2015 whichare each herein incorporated by reference in their respective entirety:

-   -   U.S. patent application Ser. No. 14/984,488, entitled MECHANISMS        FOR COMPENSATING FOR BATTERY PACK FAILURE IN POWERED SURGICAL        INSTRUMENTS;    -   U.S. patent application Ser. No. 14/984,525, entitled MECHANISMS        FOR COMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL        INSTRUMENTS; and    -   U.S. patent application Ser. No. 14/984,552, entitled SURGICAL        INSTRUMENTS WITH SEPARABLE MOTORS AND MOTOR CONTROL CIRCUITS.

Applicant of the present application also owns the U.S. PatentApplications identified below which were filed on Feb. 9, 2016 which areeach herein incorporated by reference in their respective entirety:

-   -   U.S. patent application Ser. No. 15/019,220, entitled SURGICAL        INSTRUMENT WITH ARTICULATING AND AXIALLY TRANSLATABLE END        EFFECTOR;    -   U.S. patent application Ser. No. 15/019,228, entitled SURGICAL        INSTRUMENTS WITH MULTIPLE LINK ARTICULATION ARRANGEMENTS;    -   U.S. patent application Ser. No. 15/019,196, entitled SURGICAL        INSTRUMENT ARTICULATION MECHANISM WITH SLOTTED SECONDARY        CONSTRAINT;    -   U.S. patent application Ser. No. 15/019,206, entitled SURGICAL        INSTRUMENTS WITH AN END EFFECTOR THAT IS HIGHLY ARTICULATABLE        RELATIVE TO AN ELONGATE SHAFT ASSEMBLY;    -   U.S. patent application Ser. No. 15/019,215, entitled SURGICAL        INSTRUMENTS WITH NON-SYMMETRICAL ARTICULATION ARRANGEMENTS;    -   U.S. patent application Ser. No. 15/019,227, entitled        ARTICULATABLE SURGICAL INSTRUMENTS WITH SINGLE ARTICULATION LINK        ARRANGEMENTS;    -   U.S. patent application Ser. No. 15/019,235, entitled SURGICAL        INSTRUMENTS WITH TENSIONING ARRANGEMENTS FOR CABLE DRIVEN        ARTICULATION SYSTEMS;    -   U.S. patent application Ser. No. 15/019,230, entitled        ARTICULATABLE SURGICAL INSTRUMENTS WITH OFF-AXIS FIRING BEAM        ARRANGEMENTS; and    -   U.S. patent application Ser. No. 15/019,245, entitled SURGICAL        INSTRUMENTS WITH CLOSURE STROKE REDUCTION ARRANGEMENTS.

Applicant of the present application also owns the U.S. PatentApplications identified below which were filed on Feb. 12, 2016 whichare each herein incorporated by reference in their respective entirety:

-   -   U.S. patent application Ser. No. 15/043,254, entitled MECHANISMS        FOR COMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL        INSTRUMENTS;    -   U.S. patent application Ser. No. 15/043,259, entitled MECHANISMS        FOR COMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL        INSTRUMENTS;    -   U.S. patent application Ser. No. 15/043,275, entitled MECHANISMS        FOR COMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL        INSTRUMENTS; and    -   U.S. patent application Ser. No. 15/043,289, entitled MECHANISMS        FOR COMPENSATING FOR DRIVETRAIN FAILURE IN POWERED SURGICAL        INSTRUMENTS.

Applicant of the present application owns the following patentapplications that were filed on Jun. 18, 2015 and which are each hereinincorporated by reference in their respective entirety:

-   -   U.S. patent application Ser. No. 14/742,925, entitled SURGICAL        END EFFECTORS WITH POSITIVE JAW OPENING ARRANGEMENTS, now U.S.        Patent Application Publication No. 2016/0367256;    -   U.S. patent application Ser. No. 14/742,941, entitled SURGICAL        END EFFECTORS WITH DUAL CAM ACTUATED JAW CLOSING FEATURES, now        U.S. Patent Application Publication No. 2016/0367248;    -   U.S. patent application Ser. No. 14/742,914, entitled MOVABLE        FIRING BEAM SUPPORT ARRANGEMENTS FOR ARTICULATABLE SURGICAL        INSTRUMENTS, now U.S. Patent Application Publication No.        2016/0367255;    -   U.S. patent application Ser. No. 14/742,900, entitled        ARTICULATABLE SURGICAL INSTRUMENTS WITH COMPOSITE FIRING BEAM        STRUCTURES WITH CENTER FIRING SUPPORT MEMBER FOR ARTICULATION        SUPPORT, now U.S. Patent Application Publication No.        2016/0367254;    -   U.S. patent application Ser. No. 14/742,885, entitled DUAL        ARTICULATION DRIVE SYSTEM ARRANGEMENTS FOR ARTICULATABLE        SURGICAL INSTRUMENTS, now U.S. Patent Application Publication        No. 2016/0367246; and    -   U.S. patent application Ser. No. 14/742,876, entitled PUSH/PULL        ARTICULATION DRIVE SYSTEMS FOR ARTICULATABLE SURGICAL        INSTRUMENTS, now U.S. Patent Application Publication No.        2016/0367245.

Applicant of the present application owns the following patentapplications that were filed on Mar. 6, 2015 and which are each hereinincorporated by reference in their respective entirety:

-   -   U.S. patent application Ser. No. 14/640,746, entitled POWERED        SURGICAL INSTRUMENT, now U.S. Patent Application Publication No.        2016/0256184;    -   U.S. patent application Ser. No. 14/640,795, entitled MULTIPLE        LEVEL THRESHOLDS TO MODIFY OPERATION OF POWERED SURGICAL        INSTRUMENTS, now U.S. Patent Application Publication No.        2016/02561185;    -   U.S. patent application Ser. No. 14/640,832, entitled ADAPTIVE        TISSUE COMPRESSION TECHNIQUES TO ADJUST CLOSURE RATES FOR        MULTIPLE TISSUE TYPES, now U.S. Patent Application Publication        No. 2016/0256154;    -   U.S. patent application Ser. No. 14/640,935, entitled OVERLAID        MULTI SENSOR RADIO FREQUENCY (RF) ELECTRODE SYSTEM TO MEASURE        TISSUE COMPRESSION, now U.S. Patent Application Publication No.        2016/0256071;    -   U.S. patent application Ser. No. 14/640,831, entitled MONITORING        SPEED CONTROL AND PRECISION INCREMENTING OF MOTOR FOR POWERED        SURGICAL INSTRUMENTS, now U.S. Patent Application Publication        No. 2016/0256153;    -   U.S. patent application Ser. No. 14/640,859, entitled TIME        DEPENDENT EVALUATION OF SENSOR DATA TO DETERMINE STABILITY,        CREEP, AND VISCOELASTIC ELEMENTS OF MEASURES, now U.S. Patent        Application Publication No. 2016/0256187;    -   U.S. patent application Ser. No. 14/640,817, entitled        INTERACTIVE FEEDBACK SYSTEM FOR POWERED SURGICAL INSTRUMENTS,        now U.S. Patent Application Publication No. 2016/0256186;    -   U.S. patent application Ser. No. 14/640,844, entitled CONTROL        TECHNIQUES AND SUB-PROCESSOR CONTAINED WITHIN MODULAR SHAFT WITH        SELECT CONTROL PROCESSING FROM HANDLE, now U.S. Patent        Application Publication No. 2016/0256155;    -   U.S. patent application Ser. No. 14/640,837, entitled SMART        SENSORS WITH LOCAL SIGNAL PROCESSING, now U.S. Patent        Application Publication No. 2016/0256163;    -   U.S. patent application Ser. No. 14/640,765, entitled SYSTEM FOR        DETECTING THE MIS-INSERTION OF A STAPLE CARTRIDGE INTO A        SURGICAL STAPLE/FASTENER, now U.S. Patent Application        Publication No. 2016/0256160;    -   U.S. patent application Ser. No. 14/640,799, entitled SIGNAL AND        POWER COMMUNICATION SYSTEM POSITIONED ON A ROTATABLE SHAFT, now        U.S. Patent Application Publication No. 2016/0256162; and    -   U.S. patent application Ser. No. 14/640,780, entitled SURGICAL        INSTRUMENT COMPRISING A LOCKABLE BATTERY HOUSING, now U.S.        Patent Application Publication No. 2016/0256161.

Applicant of the present application owns the following patentapplications that were filed on Feb. 27, 2015, and which are each hereinincorporated by reference in their respective entirety:

-   -   U.S. patent application Ser. No. 14/633,576, entitled SURGICAL        INSTRUMENT SYSTEM COMPRISING AN INSPECTION STATION, now U.S.        Patent Application Publication No. 2016/0249919;    -   U.S. patent application Ser. No. 14/633,546, entitled SURGICAL        APPARATUS CONFIGURED TO ASSESS WHETHER A PERFORMANCE PARAMETER        OF THE SURGICAL APPARATUS IS WITHIN AN ACCEPTABLE PERFORMANCE        BAND, now U.S. Patent Application Publication No. 2016/0249915;    -   U.S. patent application Ser. No. 14/633,560, entitled SURGICAL        CHARGING SYSTEM THAT CHARGES AND/OR CONDITIONS ONE OR MORE        BATTERIES, now U.S. Patent Application Publication No.        2016/0249910;    -   U.S. patent application Ser. No. 14/633,566, entitled CHARGING        SYSTEM THAT ENABLES EMERGENCY RESOLUTIONS FOR CHARGING A        BATTERY, now U.S. Patent Application Publication No.        2016/0249918;    -   U.S. patent application Ser. No. 14/633,555, entitled SYSTEM FOR        MONITORING WHETHER A SURGICAL INSTRUMENT NEEDS TO BE SERVICED,        now U.S. Patent Application Publication No. 2016/0249916;    -   U.S. patent application Ser. No. 14/633,542, entitled REINFORCED        BATTERY FOR A SURGICAL INSTRUMENT, now U.S. Patent Application        Publication No. 2016/0249908;    -   U.S. patent application Ser. No. 14/633,548, entitled POWER        ADAPTER FOR A SURGICAL INSTRUMENT, now U.S. Patent Application        Publication No. 2016/0249909;    -   U.S. patent application Ser. No. 14/633,526, entitled ADAPTABLE        SURGICAL INSTRUMENT HANDLE, now U.S. Patent Application        Publication No. 2016/0249945;    -   U.S. patent application Ser. No. 14/633,541, entitled MODULAR        STAPLING ASSEMBLY, now U.S. Patent Application Publication No.        2016/0249927; and    -   U.S. patent application Ser. No. 14/633,562, entitled SURGICAL        APPARATUS CONFIGURED TO TRACK AN END-OF-LIFE PARAMETER, now U.S.        Patent Application Publication No. 2016/0249917.

Applicant of the present application owns the following patentapplications that were filed on Dec. 18, 2014 and which are each hereinincorporated by reference in their respective entirety:

-   -   U.S. patent application Ser. No. 14/574,478, entitled SURGICAL        INSTRUMENT SYSTEMS COMPRISING AN ARTICULATABLE END EFFECTOR AND        MEANS FOR ADJUSTING THE FIRING STROKE OF A FIRING MEMBER, now        U.S. Patent Application Publication No. 2016/0174977;    -   U.S. patent application Ser. No. 14/574,483, entitled SURGICAL        INSTRUMENT ASSEMBLY COMPRISING LOCKABLE SYSTEMS, now U.S. Patent        Application Publication No. 2016/0174969;    -   U.S. patent application Ser. No. 14/575,139, entitled DRIVE        ARRANGEMENTS FOR ARTICULATABLE SURGICAL INSTRUMENTS, now U.S.        Patent Application Publication No. 2016/0174978;    -   U.S. patent application Ser. No. 14/575,148, entitled LOCKING        ARRANGEMENTS FOR DETACHABLE SHAFT ASSEMBLIES WITH ARTICULATABLE        SURGICAL END EFFECTORS, now U.S. Patent Application Publication        No. 2016/0174976;    -   U.S. patent application Ser. No. 14/575,130, entitled SURGICAL        INSTRUMENT WITH AN ANVIL THAT IS SELECTIVELY MOVABLE ABOUT A        DISCRETE NON-MOVABLE AXIS RELATIVE TO A STAPLE CARTRIDGE, now        U.S. Patent Application Publication No. 2016/0174972;    -   U.S. patent application Ser. No. 14/575,143, entitled SURGICAL        INSTRUMENTS WITH IMPROVED CLOSURE ARRANGEMENTS, now U.S. Patent        Application Publication No. 2016/0174983;    -   U.S. patent application Ser. No. 14/575,117, entitled SURGICAL        INSTRUMENTS WITH ARTICULATABLE END EFFECTORS AND MOVABLE FIRING        BEAM SUPPORT ARRANGEMENTS, now U.S. Patent Application        Publication No. 2016/0174975;    -   U.S. patent application Ser. No. 14/575,154, entitled SURGICAL        INSTRUMENTS WITH ARTICULATABLE END EFFECTORS AND IMPROVED FIRING        BEAM SUPPORT ARRANGEMENTS, now U.S. Patent Application        Publication No. 2016/0174973;    -   U.S. patent application Ser. No. 14/574,493, entitled SURGICAL        INSTRUMENT ASSEMBLY COMPRISING A FLEXIBLE ARTICULATION SYSTEM,        now U.S. Patent Application Publication No. 2016/0174970; and    -   U.S. patent application Ser. No. 14/574,500, entitled SURGICAL        INSTRUMENT ASSEMBLY COMPRISING A LOCKABLE ARTICULATION SYSTEM,        now U.S. Patent Application Publication No. 2016/0174971.

Applicant of the present application owns the following patentapplications that were filed on Mar. 1, 2013 and which are each hereinincorporated by reference in their respective entirety:

-   -   U.S. patent application Ser. No. 13/782,295, entitled        ARTICULATABLE SURGICAL INSTRUMENTS WITH CONDUCTIVE PATHWAYS FOR        SIGNAL COMMUNICATION, now U.S. Patent Application Publication        No. 2014/0246471;    -   U.S. patent application Ser. No. 13/782,323, entitled ROTARY        POWERED ARTICULATION JOINTS FOR SURGICAL INSTRUMENTS, now U.S.        Patent Application Publication No. 2014/0246472;    -   U.S. patent application Ser. No. 13/782,338, entitled THUMBWHEEL        SWITCH ARRANGEMENTS FOR SURGICAL INSTRUMENTS, now U.S. Patent        Application Publication No. 2014/0249557;    -   U.S. patent application Ser. No. 13/782,499, entitled        ELECTROMECHANICAL SURGICAL DEVICE WITH SIGNAL RELAY ARRANGEMENT,        now U.S. Pat. No. 9,358,003;    -   U.S. patent application Ser. No. 13/782,460, entitled MULTIPLE        PROCESSOR MOTOR CONTROL FOR MODULAR SURGICAL INSTRUMENTS, now        U.S. Pat. No. 9,554,794;    -   U.S. patent application Ser. No. 13/782,358, entitled JOYSTICK        SWITCH ASSEMBLIES FOR SURGICAL INSTRUMENTS, now U.S. Pat. No.        9,326,767;    -   U.S. patent application Ser. No. 13/782,481, entitled SENSOR        STRAIGHTENED END EFFECTOR DURING REMOVAL THROUGH TROCAR, now        U.S. Pat. No. 9,468,438;    -   U.S. patent application Ser. No. 13/782,518, entitled CONTROL        METHODS FOR SURGICAL INSTRUMENTS WITH REMOVABLE IMPLEMENT        PORTIONS, now U.S. Patent Application Publication No.        2014/0246475;    -   U.S. patent application Ser. No. 13/782,375, entitled ROTARY        POWERED SURGICAL INSTRUMENTS WITH MULTIPLE DEGREES OF FREEDOM,        now U.S. Pat. No. 9,398,911; and    -   U.S. patent application Ser. No. 13/782,536, entitled SURGICAL        INSTRUMENT SOFT STOP, now U.S. Pat. No. 9,307,986.

Applicant of the present application also owns the following patentapplications that were filed on Mar. 14, 2013 and which are each hereinincorporated by reference in their respective entirety:

-   -   U.S. patent application Ser. No. 13/803,097, entitled        ARTICULATABLE SURGICAL INSTRUMENT COMPRISING A FIRING DRIVE, now        U.S. Patent Application Publication No. 2014/0263542;    -   U.S. patent application Ser. No. 13/803,193, entitled CONTROL        ARRANGEMENTS FOR A DRIVE MEMBER OF A SURGICAL INSTRUMENT, now        U.S. Pat. No. 9,332,987;    -   U.S. patent application Ser. No. 13/803,053, entitled        INTERCHANGEABLE SHAFT ASSEMBLIES FOR USE WITH A SURGICAL        INSTRUMENT, now U.S. Patent Application Publication No.        2014/0263564;    -   U.S. patent application Ser. No. 13/803,086, entitled        ARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN ARTICULATION        LOCK, now U.S. Patent Application Publication No. 2014/0263541;    -   U.S. patent application Ser. No. 13/803,210, entitled SENSOR        ARRANGEMENTS FOR ABSOLUTE POSITIONING SYSTEM FOR SURGICAL        INSTRUMENTS, now U.S. Patent Application Publication No.        2014/0263538;    -   U.S. patent application Ser. No. 13/803,148, entitled        MULTI-FUNCTION MOTOR FOR A SURGICAL INSTRUMENT, now U.S. Patent        Application Publication No. 2014/0263554;    -   U.S. patent application Ser. No. 13/803,066, entitled DRIVE        SYSTEM LOCKOUT ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS,        now U.S. Pat. No. 9,629,623;    -   U.S. patent application Ser. No. 13/803,117, entitled        ARTICULATION CONTROL SYSTEM FOR ARTICULATABLE SURGICAL        INSTRUMENTS, now U.S. Pat. No. 9,351,726;    -   U.S. patent application Ser. No. 13/803,130, entitled DRIVE        TRAIN CONTROL ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS, now        U.S. Pat. No. 9,351,727; and    -   U.S. patent application Ser. No. 13/803,159, entitled METHOD AND        SYSTEM FOR OPERATING A SURGICAL INSTRUMENT, now U.S. Patent        Application Publication No. 2014/0277017.

Applicant of the present application also owns the following patentapplication that was filed on Mar. 7, 2014 and is herein incorporated byreference in its entirety:

-   -   U.S. patent application Ser. No. 14/200,111, entitled CONTROL        SYSTEMS FOR SURGICAL INSTRUMENTS, now U.S. Pat. No. 9,629,629.

Applicant of the present application also owns the following patentapplications that were filed on Mar. 26, 2014 and are each hereinincorporated by reference in their respective entirety:

-   -   U.S. patent application Ser. No. 14/226,106, entitled POWER        MANAGEMENT CONTROL SYSTEMS FOR SURGICAL INSTRUMENTS, now U.S.        Patent Application Publication No. 2015/0272582;    -   U.S. patent application Ser. No. 14/226,099, entitled        STERILIZATION VERIFICATION CIRCUIT, now U.S. Patent Application        Publication No. 2015/0272581;    -   U.S. patent application Ser. No. 14/226,094, entitled        VERIFICATION OF NUMBER OF BATTERY EXCHANGES/PROCEDURE COUNT, now        U.S. Patent Application Publication No. 2015/0272580;    -   U.S. patent application Ser. No. 14/226,117, entitled POWER        MANAGEMENT THROUGH SLEEP OPTIONS OF SEGMENTED CIRCUIT AND WAKE        UP CONTROL, now U.S. Patent Application Publication No.        2015/0272574;    -   U.S. patent application Ser. No. 14/226,075, entitled MODULAR        POWERED SURGICAL INSTRUMENT WITH DETACHABLE SHAFT ASSEMBLIES,        now U.S. Patent Application Publication No. 2015/0272579;    -   U.S. patent application Ser. No. 14/226,093, entitled FEEDBACK        ALGORITHMS FOR MANUAL BAILOUT SYSTEMS FOR SURGICAL INSTRUMENTS,        now U.S. Patent Application Publication No. 2015/0272569;    -   U.S. patent application Ser. No. 14/226,116, entitled SURGICAL        INSTRUMENT UTILIZING SENSOR ADAPTATION, now U.S. Patent        Application Publication No. 2015/0272571;    -   U.S. patent application Ser. No. 14/226,071, entitled SURGICAL        INSTRUMENT CONTROL CIRCUIT HAVING A SAFETY PROCESSOR, now U.S.        Patent Application Publication No. 2015/0272578;    -   U.S. patent application Ser. No. 14/226,097, entitled SURGICAL        INSTRUMENT COMPRISING INTERACTIVE SYSTEMS, now U.S. Patent        Application Publication No. 2015/0272570;    -   U.S. patent application Ser. No. 14/226,126, entitled INTERFACE        SYSTEMS FOR USE WITH SURGICAL INSTRUMENTS, now U.S. Patent        Application Publication No. 2015/0272572;    -   U.S. patent application Ser. No. 14/226,133, entitled MODULAR        SURGICAL INSTRUMENT SYSTEM, now U.S. Patent Application        Publication No. 2015/0272557;    -   U.S. patent application Ser. No. 14/226,081, entitled SYSTEMS        AND METHODS FOR CONTROLLING A SEGMENTED CIRCUIT, now U.S. Patent        Application Publication No. 2015/0277471;    -   U.S. patent application Ser. No. 14/226,076, entitled POWER        MANAGEMENT THROUGH SEGMENTED CIRCUIT AND VARIABLE VOLTAGE        PROTECTION, now U.S. Patent Application Publication No.        2015/0280424;    -   U.S. patent application Ser. No. 14/226,111, entitled SURGICAL        STAPLING INSTRUMENT SYSTEM, now U.S. Patent Application        Publication No. 2015/0272583; and    -   U.S. patent application Ser. No. 14/226,125, entitled SURGICAL        INSTRUMENT COMPRISING A ROTATABLE SHAFT, now U.S. Patent        Application Publication No. 2015/0280384.

Applicant of the present application also owns the following patentapplications that were filed on Sep. 5, 2014 and which are each hereinincorporated by reference in their respective entirety:

-   -   U.S. patent application Ser. No. 14/479,103, entitled CIRCUITRY        AND SENSORS FOR POWERED MEDICAL DEVICE, now U.S. Patent        Application Publication No. 2016/0066912;    -   U.S. patent application Ser. No. 14/479,119, entitled ADJUNCT        WITH INTEGRATED SENSORS TO QUANTIFY TISSUE COMPRESSION, now U.S.        Patent Application Publication No. 2016/0066914;    -   U.S. patent application Ser. No. 14/478,908, entitled MONITORING        DEVICE DEGRADATION BASED ON COMPONENT EVALUATION, now U.S.        Patent Application Publication No. 2016/0066910;    -   U.S. patent application Ser. No. 14/478,895, entitled MULTIPLE        SENSORS WITH ONE SENSOR AFFECTING A SECOND SENSOR′S OUTPUT OR        INTERPRETATION, now U.S. Patent Application Publication No.        2016/0066909;    -   U.S. patent application Ser. No. 14/479,110, entitled POLARITY        OF HALL MAGNET TO DETECT MISLOADED CARTRIDGE, now U.S. Patent        Application Publication No. 2016/0066915;    -   U.S. patent application Ser. No. 14/479,098, entitled SMART        CARTRIDGE WAKE UP OPERATION AND DATA RETENTION, now U.S. Patent        Application Publication No. 2016/0066911;    -   U.S. patent application Ser. No. 14/479,115, entitled MULTIPLE        MOTOR CONTROL FOR POWERED MEDICAL DEVICE, now U.S. Patent        Application Publication No. 2016/0066916; and    -   U.S. patent application Ser. No. 14/479,108, entitled LOCAL        DISPLAY OF TISSUE PARAMETER STABILIZATION, now U.S. Patent        Application Publication No. 2016/0066913.

Applicant of the present application also owns the following patentapplications that were filed on Apr. 9, 2014 and which are each hereinincorporated by reference in their respective entirety:

-   -   U.S. patent application Ser. No. 14/248,590, entitled MOTOR        DRIVEN SURGICAL INSTRUMENTS WITH LOCKABLE DUAL DRIVE SHAFTS, now        U.S. Patent Application Publication No. 2014/0305987;    -   U.S. patent application Ser. No. 14/248,581, entitled SURGICAL        INSTRUMENT COMPRISING A CLOSING DRIVE AND A FIRING DRIVE        OPERATED FROM THE SAME ROTATABLE OUTPUT, now U.S. Pat. No.        9,649,110;    -   U.S. patent application Ser. No. 14/248,595, entitled SURGICAL        INSTRUMENT SHAFT INCLUDING SWITCHES FOR CONTROLLING THE        OPERATION OF THE SURGICAL INSTRUMENT, now U.S. Patent        Application Publication No. 2014/0305988;    -   U.S. patent application Ser. No. 14/248,588, entitled POWERED        LINEAR SURGICAL STAPLE/FASTENER, now U.S. Patent Application        Publication No. 2014/0309666;    -   U.S. patent application Ser. No. 14/248,591, entitled        TRANSMISSION ARRANGEMENT FOR A SURGICAL INSTRUMENT, now U.S.        Patent Application Publication No. 2014/0305991;    -   U.S. patent application Ser. No. 14/248,584, entitled MODULAR        MOTOR DRIVEN SURGICAL INSTRUMENTS WITH ALIGNMENT FEATURES FOR        ALIGNING ROTARY DRIVE SHAFTS WITH SURGICAL END EFFECTOR SHAFTS,        now U.S. Patent Application Publication No. 2014/0305994;    -   U.S. patent application Ser. No. 14/248,587, entitled POWERED        SURGICAL STAPLE/FASTENER, now U.S. Patent Application        Publication No. 2014/0309665;    -   U.S. patent application Ser. No. 14/248,586, entitled DRIVE        SYSTEM DECOUPLING ARRANGEMENT FOR A SURGICAL INSTRUMENT, now        U.S. Patent Application Publication No. 2014/0305990; and    -   U.S. patent application Ser. No. 14/248,607, entitled MODULAR        MOTOR DRIVEN SURGICAL INSTRUMENTS WITH STATUS INDICATION        ARRANGEMENTS, now U.S. Patent Application Publication No.        2014/0305992.

Applicant of the present application also owns the following patentapplications that were filed on Apr. 16, 2013 and which are each hereinincorporated by reference in their respective entirety:

-   -   U.S. Provisional Patent Application Ser. No. 61/812,365,        entitled SURGICAL INSTRUMENT WITH MULTIPLE FUNCTIONS PERFORMED        BY A SINGLE MOTOR;    -   U.S. Provisional Patent Application Ser. No. 61/812,376,        entitled LINEAR CUTTER WITH POWER;    -   U.S. Provisional Patent Application Ser. No. 61/812,382,        entitled LINEAR CUTTER WITH MOTOR AND PISTOL GRIP;    -   U.S. Provisional Patent Application Ser. No. 61/812,385,        entitled SURGICAL INSTRUMENT HANDLE WITH MULTIPLE ACTUATION        MOTORS AND MOTOR CONTROL; and    -   U.S. Provisional Patent Application Ser. No. 61/812,372,        entitled SURGICAL INSTRUMENT WITH MULTIPLE FUNCTIONS PERFORMED        BY A SINGLE MOTOR.

Numerous specific details are set forth to provide a thoroughunderstanding of the overall structure, function, manufacture, and useof the embodiments as described in the specification and illustrated inthe accompanying drawings. Well-known operations, components, andelements have not been described in detail so as not to obscure theembodiments described in the specification. The reader will understandthat the embodiments described and illustrated herein are non-limitingexamples, and thus it can be appreciated that the specific structuraland functional details disclosed herein may be representative andillustrative. Variations and changes thereto may be made withoutdeparting from the scope of the claims.

The terms “comprise” (and any form of comprise, such as “comprises” and“comprising”), “have” (and any form of have, such as “has” and“having”), “include” (and any form of include, such as “includes” and“including”) and “contain” (and any form of contain, such as “contains”and “containing”) are open-ended linking verbs. As a result, a surgicalsystem, device, or apparatus that “comprises,” “has,” “includes” or“contains” one or more elements possesses those one or more elements,but is not limited to possessing only those one or more elements.Likewise, an element of a system, device, or apparatus that “comprises,”“has,” “includes” or “contains” one or more features possesses those oneor more features, but is not limited to possessing only those one ormore features.

The terms “proximal” and “distal” are used herein with reference to aclinician manipulating the handle portion of the surgical instrument.The term “proximal” refers to the portion closest to the clinician andthe term “distal” refers to the portion located away from the clinician.It will be further appreciated that, for convenience and clarity,spatial terms such as “vertical”, “horizontal”, “up”, and “down” may beused herein with respect to the drawings. However, surgical instrumentsare used in many orientations and positions, and these terms are notintended to be limiting and/or absolute.

Various exemplary devices and methods are provided for performinglaparoscopic and minimally invasive surgical procedures. However, thereader will readily appreciate that the various methods and devicesdisclosed herein can be used in numerous surgical procedures andapplications including, for example, in connection with open surgicalprocedures. As the present Detailed Description proceeds, the readerwill further appreciate that the various instruments disclosed hereincan be inserted into a body in any way, such as through a naturalorifice, through an incision or puncture hole formed in tissue, etc. Theworking portions or end effector portions of the instruments can beinserted directly into a patient's body or can be inserted through anaccess device that has a working channel through which the end effectorand elongate shaft of a surgical instrument can be advanced.

A surgical stapling system can comprise a shaft and an end effectorextending from the shaft. The end effector comprises a first jaw and asecond jaw. The first jaw comprises a staple cartridge. The staplecartridge is insertable into and removable from the first jaw; however,other embodiments are envisioned in which a staple cartridge is notremovable from, or at least readily replaceable from, the first jaw. Thesecond jaw comprises an anvil configured to deform staples ejected fromthe staple cartridge. The second jaw is pivotable relative to the firstjaw about a closure axis; however, other embodiments are envisioned inwhich the first jaw is pivotable relative to the second jaw. Thesurgical stapling system further comprises an articulation jointconfigured to permit the end effector to be rotated, or articulated,relative to the shaft. The end effector is rotatable about anarticulation axis extending through the articulation joint. Otherembodiments are envisioned which do not include an articulation joint.

The staple cartridge comprises a cartridge body. The cartridge bodyincludes a proximal end, a distal end, and a deck extending between theproximal end and the distal end. In use, the staple cartridge ispositioned on a first side of the tissue to be stapled and the anvil ispositioned on a second side of the tissue. The anvil is moved toward thestaple cartridge to compress and clamp the tissue against the deck.Thereafter, staples removably stored in the cartridge body can bedeployed into the tissue. The cartridge body includes staple cavitiesdefined therein wherein staples are removably stored in the staplecavities. The staple cavities are arranged in six longitudinal rows.Three rows of staple cavities are positioned on a first side of alongitudinal slot and three rows of staple cavities are positioned on asecond side of the longitudinal slot. Other arrangements of staplecavities and staples may be possible.

The staples are supported by staple drivers in the cartridge body. Thedrivers are movable between a first, or unfired position, and a second,or fired, position to eject the staples from the staple cavities. Thedrivers are retained in the cartridge body by a retainer which extendsaround the bottom of the cartridge body and includes resilient membersconfigured to grip the cartridge body and hold the retainer to thecartridge body. The drivers are movable between their unfired positionsand their fired positions by a sled. The sled is movable between aproximal position adjacent the proximal end and a distal positionadjacent the distal end. The sled comprises a plurality of rampedsurfaces configured to slide under the drivers and lift the drivers, andthe staples supported thereon, toward the anvil.

Further to the above, the sled is moved distally by a firing member. Thefiring member is configured to contact the sled and push the sled towardthe distal end. The longitudinal slot defined in the cartridge body isconfigured to receive the firing member. The anvil also includes a slotconfigured to receive the firing member. The firing member furthercomprises a first cam which engages the first jaw and a second cam whichengages the second jaw. As the firing member is advanced distally, thefirst cam and the second cam can control the distance, or tissue gap,between the deck of the staple cartridge and the anvil. The firingmember also comprises a knife configured to incise the tissue capturedintermediate the staple cartridge and the anvil. It is desirable for theknife to be positioned at least partially proximal to the rampedsurfaces such that the staples are ejected ahead of the knife.

FIG. 1 depicts a motor-driven surgical system 10 that may be used toperform a variety of different surgical procedures. As can be seen inthat Figure, one example of the surgical system 10 includes fourinterchangeable surgical tool assemblies 100, 200, 300, and 1000 thatare each adapted for interchangeable use with a handle assembly 500.Each interchangeable surgical tool assembly 100, 200, 300, and 1000 maybe designed for use in connection with the performance of one or morespecific surgical procedures. In another surgical system embodiment, theinterchangeable surgical tool assemblies may be effectively employedwith a tool drive assembly of a robotically controlled or automatedsurgical system. For example, the surgical tool assemblies disclosedherein may be employed with various robotic systems, instruments,components and methods such as, but not limited to, those disclosed inU.S. Pat. No. 9,072,535, entitled SURGICAL STAPLING INSTRUMENTS WITHROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, which is hereby incorporatedby reference herein in its entirety.

FIG. 2 illustrates one form of an interchangeable surgical tool assembly100 that is operably coupled to the handle assembly 500. FIG. 3illustrates attachment of the interchangeable surgical tool assembly 100to the handle assembly 500. The attachment arrangement and processdepicted in FIG. 3 may also be employed in connection with attachment ofany of the interchangeable surgical tool assemblies 100, 200, 300, and1000 to a tool drive portion or tool drive housing of a robotic system.The handle assembly 500 may comprise a handle housing 502 that includesa pistol grip portion 504 that can be gripped and manipulated by theclinician. As will be briefly discussed below, the handle assembly 500operably supports a plurality of drive systems that are configured togenerate and apply various control motions to corresponding portions ofthe interchangeable surgical tool assembly 100, 200, 300, and/or 1000that is operably attached thereto.

Referring now to FIG. 3, the handle assembly 500 may further include aframe 506 that operably supports the plurality of drive systems. Forexample, the frame 506 can operably support a first or closure drivesystem, generally designated as 510, which may be employed to applyclosing and opening motions to the interchangeable surgical toolassembly 100, 200, 300, and 1000 that is operably attached or coupled tothe handle assembly 500. In at least one form, the closure drive system510 may include an actuator in the form of a closure trigger 512 that ispivotally supported by the frame 506. Such an arrangement enables theclosure trigger 512 to be manipulated by a clinician such that, when theclinician grips the pistol grip portion 504 of the handle assembly 500,the closure trigger 512 may be pivoted from a starting or “unactuated”position to an “actuated” position and more particularly to a fullycompressed or fully actuated position. In various forms, the closuredrive system 510 further includes a closure linkage assembly 514 that ispivotally coupled to the closure trigger 512 or otherwise operablyinterfaces therewith. As will be discussed in further detail below, theclosure linkage assembly 514 includes a transverse attachment pin 516that facilitates attachment to a corresponding drive system on thesurgical tool assembly. To actuate the closure drive system, theclinician depresses the closure trigger 512 towards the pistol gripportion 504. As described in further detail in U.S. patent applicationSer. No. 14/226,142, entitled SURGICAL INSTRUMENT COMPRISING A SENSORSYSTEM, now U.S. Patent Application Publication No. 2015/0272575, whichis hereby incorporated by reference in its entirety herein, the closuredrive system is configured to lock the closure trigger 512 into thefully depressed or fully actuated position when the clinician fullydepresses the closure trigger 512 to attain the full closure stroke.When the clinician desires to unlock the closure trigger 512 to permitthe closure trigger 512 to be biased to the unactuated position, theclinician simply activates a closure release button assembly 518 whichenables the closure trigger to return to unactuated position. Theclosure release button 518 may also be configured to interact withvarious sensors that communicate with a microcontroller 520 in thehandle assembly 500 for tracking the position of the closure trigger512. Further details concerning the configuration and operation of theclosure release button assembly 518 may be found in U.S. PatentApplication Publication No. 2015/0272575.

In at least one form, the handle assembly 500 and the frame 506 mayoperably support another drive system referred to herein as a firingdrive system 530 that is configured to apply firing motions tocorresponding portions of the interchangeable surgical tool assemblythat is attached thereto. As was described in detail in U.S. PatentApplication Publication No. 2015/0272575, the firing drive system 530may employ an electric motor (not shown in FIGS. 1-3) that is located inthe pistol grip portion 504 of the handle assembly 500. In variousforms, the motor may be a DC brushed driving motor having a maximumspeed of approximately 25,000 RPM, for example. In other arrangements,the motor may include a brushless motor, a cordless motor, a synchronousmotor, a stepper motor, or any other suitable electric motor. The motormay be powered by a power source 522 that in one form may comprise aremovable power pack. The power pack may support a plurality of LithiumIon (“LI”) or other suitable batteries therein. A number of batteriesmay be connected in series may be used as the power source 522 for thesurgical system 10. In addition, the power source 522 may be replaceableand/or rechargeable.

The electric motor is configured to axially drive a longitudinallymovable drive member 540 in distal and proximal directions dependingupon the polarity of the voltage applied to the motor. For example, whenthe motor is driven in one rotary direction, the longitudinally movabledrive member 540 the will be axially driven in the distal direction“DD”. When the motor is driven in the opposite rotary direction, thelongitudinally movable drive member 540 will be axially driven in aproximal direction “PD”. The handle assembly 500 can include a switch513 which can be configured to reverse the polarity applied to theelectric motor by the power source 522 or otherwise control the motor.The handle assembly 500 can also include a sensor or sensors that areconfigured to detect the position of the drive member 540 and/or thedirection in which the drive member 540 is being moved. Actuation of themotor can be controlled by a firing trigger 532 (FIG. 1) that ispivotally supported on the handle assembly 500. The firing trigger 532may be pivoted between an unactuated position and an actuated position.The firing trigger 532 may be biased into the unactuated position by aspring or other biasing arrangement such that, when the clinicianreleases the firing trigger 532, the firing trigger 532 may be pivotedor otherwise returned to the unactuated position by the spring orbiasing arrangement. In at least one form, the firing trigger 532 can bepositioned “outboard” of the closure trigger 512 as was discussed above.As discussed in U.S. Patent Application Publication No. 2015/0272575,the handle assembly 500 may be equipped with a firing trigger safetybutton to prevent inadvertent actuation of the firing trigger 532. Whenthe closure trigger 512 is in the unactuated position, the safety buttonis contained in the handle assembly 500 where the clinician cannotreadily access the safety button and move it between a safety positionpreventing actuation of the firing trigger 532 and a firing positionwherein the firing trigger 532 may be fired. As the clinician depressesthe closure trigger 512, the safety button and the firing trigger 532pivot downwardly where they can then be manipulated by the clinician.

In at least one form, the longitudinally movable drive member 540 mayhave a rack of teeth formed thereon for meshing engagement with acorresponding drive gear arrangement that interfaces with the motor.Further details regarding those features may be found in U.S. PatentApplication Publication No. 2015/0272575. In at least one form, thehandle assembly 500 also includes a manually-actuatable “bailout”assembly that is configured to enable the clinician to manually retractthe longitudinally movable drive member 540 should the motor becomedisabled. The bailout assembly may include a lever or bailout handleassembly that is stored within the handle assembly 500 under areleasable door 550. The lever is configured to be manually pivoted intoratcheting engagement with the teeth in the drive member 540. Thus, theclinician can manually retract the drive member 540 by using the bailouthandle assembly to ratchet the drive member 5400 in the proximaldirection “PD”. U.S. patent application Ser. No. 12/249,117, entitledPOWERED SURGICAL CUTTING AND STAPLING APPARATUS WITH MANUALLYRETRACTABLE FIRING SYSTEM, now U.S. Pat. No. 8,608,045, the entiredisclosure of which is hereby incorporated by reference herein,discloses bailout arrangements that may also be employed with thevarious surgical tool assemblies disclosed herein.

Turning now to FIG. 2, the interchangeable surgical tool assembly 100includes a surgical end effector 110 that comprises a first jaw and asecond jaw. In one arrangement, the first jaw comprises an elongatechannel 112 that is configured to operably support a surgical staplecartridge 116 therein. The second jaw comprises an anvil 114 that ispivotally supported relative to the elongate channel 112. Theinterchangeable surgical tool assembly 100 also includes a lockablearticulation joint 120 which can be configured to releasably hold theend effector 110 in a desired position relative to a shaft axis SA.Details regarding various constructions and operation of the endeffector 110, the articulation joint 120 and the articulation lock areset forth in U.S. patent application Ser. No. 13/803,086, entitledARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK, nowU.S. Patent Application Publication No. 2014/0263541, which is herebyincorporated by reference herein in its entirety. As can be further seenin FIGS. 2 and 3, the interchangeable surgical tool assembly 100 caninclude a proximal housing or nozzle 130 and a closure tube assembly 140which can be utilized to close and/or open the anvil 114 of the endeffector 110. As discussed in U.S. Patent Application Publication No.2015/0272575, the closure tube assembly 140 is movably supported on aspine 145 which supports an articulation driver arrangement 147configured to apply articulation motions to the surgical end effector110. The spine 145 is configured to, one, slidably support a firing bar170 therein and, two, slidably support the closure tube assembly 140which extends around the spine 145. In various circumstances, the spine145 includes a proximal end that is rotatably supported in a chassis150. See FIG. 3. In one arrangement, for example, the proximal end ofthe spine 145 is attached to a spine bearing that is configured to besupported within the chassis 150. Such an arrangement facilitates therotatable attachment of the spine 145 to the chassis 150 such that thespine 145 may be selectively rotated about a shaft axis SA relative tothe chassis 150.

Still referring to FIG. 3, the interchangeable surgical tool assembly100 includes a closure shuttle 160 that is slidably supported within thechassis 150 such that the closure shuttle 160 may be axially movedrelative to the chassis 150. As can be seen in FIG. 3, the closureshuttle 160 includes a pair of proximally-protruding hooks 162 that areconfigured to be attached to the attachment pin 516 that is attached tothe closure linkage assembly 514 in the handle assembly 500. A proximalclosure tube segment 146 of the closure tube assembly 140 is rotatablycoupled to the closure shuttle 160. Thus, when the hooks 162 are hookedover the pin 516, actuation of the closure trigger 512 will result inthe axial movement of the closure shuttle 160 and, ultimately, theclosure tube assembly 140 on the spine 145. A closure spring may also bejournaled on the closure tube assembly 140 and serves to bias theclosure tube assembly 140 in the proximal direction “PD” which can serveto pivot the closure trigger 512 into the unactuated position when theshaft assembly 100 is operably coupled to the handle assembly 500. Inuse, the closure tube assembly 140 is translated distally (direction DD)to close the anvil 114 in response to the actuation of the closuretrigger 512. The closure tube assembly 140 includes a distal closuretube segment 142 that is pivotally pinned to a distal end of a proximalclosure tube segment 146. The distal closure tube segment 142 isconfigured to axially move with the proximal closure tube segment 146relative to the surgical end effector 110. When the distal end of thedistal closure tube segment 142 strikes a proximal surface or ledge 115on the anvil 114, the anvil 114 is pivoted closed. Further detailsconcerning the closure of anvil 114 may be found in the aforementionedU.S. Patent Application Publication No. 2014/0263541 and will bediscussed in further detail below. As was also described in detail inU.S. Patent Application Publication No. 2014/0263541, the anvil 114 isopened by proximally translating the distal closure tube segment 142.The distal closure tube segment 142 has a horseshoe aperture 143 thereinthat defines a downwardly extending return tab that cooperates with ananvil tab 117 formed on the proximal end of the anvil 114 to pivot theanvil 114 back to an open position. In the fully open position, theclosure tube assembly 140 is in its proximal-most or unactuatedposition.

As was also indicated above, the interchangeable surgical tool assembly100 further includes a firing bar 170 that is supported for axial travelwithin the shaft spine 145. The firing bar 170 includes an intermediatefiring shaft portion that is configured to be attached to a distalcutting portion or knife bar that is configured for axial travel throughthe surgical end effector 110. In at least one arrangement, theinterchangeable surgical tool assembly 100 includes a clutch assemblywhich can be configured to selectively and releasably couple thearticulation driver to the firing bar 170. Further details regarding theclutch assembly features and operation may be found in U.S. PatentApplication Publication No. 2014/0263541. As discussed in U.S. PatentApplication Publication No. 2014/0263541, distal movement of the firingbar 170 can move the articulation driver arrangement 147 distally and,correspondingly, proximal movement of the firing bar 170 can move thearticulation driver arrangement 147 proximally when the clutch assemblyis in its engaged position. When the clutch assembly is in itsdisengaged position, movement of the firing bar 170 is not transmittedto the articulation driver arrangement 147 and, as a result, the firingbar 170 can move independently of the articulation driver arrangement147. The interchangeable surgical tool assembly 100 may also include aslip ring assembly which can be configured to conduct electrical powerto and/or from the end effector 110 and/or communicate signals to and/orfrom the end effector 110. Further details regarding the slip ringassembly may be found in U.S. Patent Application Publication No.2014/0263541. U.S. patent application Ser. No. 13/800,067, entitledSTAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, now U.S. PatentApplication Publication No. 2014/0263552 is incorporated by reference inits entirety. U.S. Pat. No. 9,345,481, entitled STAPLE CARTRIDGE TISSUETHICKNESS SENSOR SYSTEM, is also hereby incorporated by reference in itsentirety.

Still referring to FIG. 3, the chassis 150 has one or more taperedattachment portions 152 formed thereon that are adapted to be receivedwithin corresponding dovetail slots 507 formed within a distal end ofthe frame 506. Each dovetail slot 507 may be tapered or, stated anotherway, may be somewhat V-shaped to seatingly receive the taperedattachment portions 152 therein. As can be further seen in FIG. 3, ashaft attachment lug 172 is formed on the proximal end of the firingshaft 170. When the interchangeable surgical tool assembly 100 iscoupled to the handle assembly 500, the shaft attachment lug 172 isreceived in a firing shaft attachment cradle 542 formed in the distalend of the longitudinally movable drive member 540. The interchangeablesurgical tool assembly 100 also employs a latch system 180 forreleasably latching the shaft assembly 100 to the frame 506 of thehandle assembly 500. In at least one form, the latch system 180 includesa lock member or lock yoke 182 that is movably coupled to the chassis150, for example. The lock yoke 182 includes two proximally protrudinglock lugs 184 that are configured for releasable engagement withcorresponding lock detents or grooves 509 in the distal attachmentflange of the frame 506. In various forms, the lock yoke 182 is biasedin the proximal direction by spring or biasing member. Actuation of thelock yoke 182 may be accomplished by a latch button 186 that is slidablymounted on a latch actuator assembly that is mounted to the chassis 150.The latch button 186 may be biased in a proximal direction relative tothe lock yoke 182. As will be discussed in further detail below, thelock yoke 182 may be moved to an unlocked position by biasing the latchbutton 186 the in distal direction DD which also causes the lock yoke182 to pivot out of retaining engagement with the distal attachmentflange of the frame 506. When the lock yoke 182 is in retainingengagement with the distal attachment flange of the frame 506, the locklugs 184 are retainingly seated within the corresponding lock detents orgrooves 509 in the distal end of the frame 506. Further detailsconcerning the latching system may be found in U.S. Patent ApplicationPublication No. 2014/0263541.

To attach the interchangeable surgical tool assembly 100 to the handleassembly 500 A clinician may position the chassis 150 of theinterchangeable surgical tool assembly 100 above or adjacent to thedistal end of the frame 506 such that the tapered attachment portions152 formed on the chassis 150 are aligned with the dovetail slots 507 inthe frame 506. The clinician may then move the surgical tool assembly100 along an installation axis IA that is perpendicular to the shaftaxis SA to seat the tapered attachment portions 152 in operableengagement with the corresponding dovetail receiving slots 507 in thedistal end of the frame 506. In doing so, the shaft attachment lug 172on the firing shaft 170 will also be seated in the cradle 542 in thelongitudinally movable drive member 540 and the portions of pin 516 onthe closure link 514 will be seated in the corresponding hooks 162 inthe closure shuttle 160. As used herein, the term “operable engagement”in the context of two components means that the two components aresufficiently engaged with each other so that, upon application of anactuation motion thereto, the components carry out their intendedaction, function, and/or procedure.

Returning now to FIG. 1, the surgical system 10 includes fourinterchangeable surgical tool assemblies 100, 200, 300, and 1000 thatmay each be effectively employed with the same handle assembly 500 toperform different surgical procedures. The construction of an exemplaryform of interchangeable surgical tool assembly 100 was briefly discussedabove and is discussed in further detail in U.S. Patent ApplicationPublication No. 2014/0263541. Various details regarding interchangeablesurgical tool assemblies 200 and 300 may be found in the various U.S.Patent Applications which have been incorporated by reference herein.Various details regarding interchangeable surgical tool assembly 1000will be discussed in further detail below.

As illustrated in FIG. 1, each of the surgical tool assemblies 100, 200,300, and 1000 includes a pair of jaws wherein at least one of the jawsis movable to capture, manipulate, and/or clamp tissue between the twojaws. The movable jaw is moved between open and closed positions uponthe application of closure and opening motions applied thereto from thehandle assembly or the robotic or automated surgical system to which thesurgical tool assembly is operably coupled. In addition, each of theillustrated interchangeable surgical tool assemblies includes a firingmember that is configured to cut tissue and fire staples from a staplecartridge that is supported in one of the jaws in response to firingmotions applied thereto by the handle assembly or robotic system. Eachsurgical tool assembly may be uniquely designed to perform a specificprocedure, for example, to cut and fasten a particular type of andthickness of tissue within a certain area in the body. The closing,firing and articulation control systems in the handle assembly 500 orrobotic system may be configured to generate axial control motionsand/or rotary control motions depending upon the type of closing,firing, and articulation system configurations that are employed in thesurgical tool assembly. In one arrangement, one of the closure systemcontrol components moves axially from an unactuated position to itsfully actuated position when a closure control system in the handleassembly or robotic system is fully actuated. The axial distance thatthe closure tube assembly moves between its unactuated position to itsfully actuated position may be referred to herein as its “closure strokelength”. Similarly, one of the firing system control components movesaxially from its unactuated position to its fully actuated or firedposition when a firing system in the handle assembly or robotic systemis fully actuated. The axial distance that the longitudinally movabledrive member moves between its unactuated position and its fully firedposition may be referred to herein as its “firing stroke length”. Forthose surgical tool assemblies that employ articulatable end effectorarrangements, the handle assembly or robotic system may employarticulation control components that move axially through an“articulation drive stroke length”. In many circumstances, the closurestroke length, the firing stroke length, and the articulation drivestroke length are fixed for a particular handle assembly or roboticsystem. Thus, each of the surgical tool assemblies must be able toaccommodate control movements of the closure, firing, and/orarticulation components through each of their entire stroke lengthswithout placing undue stress on the surgical tool components which mightlead to damage the surgical tool assembly.

Turning now to FIGS. 4-10, the interchangeable surgical tool assembly1000 includes a surgical end effector 1100 that comprises an elongatechannel 1102 that is configured to operably support a staple cartridge1110 therein. The end effector 1100 may further include an anvil 1130that is pivotally supported relative to the elongate channel 1102. Theinterchangeable surgical tool assembly 1000 may further include anarticulation joint 1200 and an articulation lock 1210 (FIGS. 5 and 8-10)which can be configured to releasably hold the end effector 1100 in adesired articulated position relative to a shaft axis SA. Detailsregarding the construction and operation of the articulation lock 1210may be found in in U.S. patent application Ser. No. 13/803,086, entitledARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK, nowU.S. Patent Application Publication No. 2014/0263541, the entiredisclosure of which is hereby incorporated by reference herein.Additional details concerning the articulation lock may also be found inU.S. patent application Ser. No. 15/019,196, filed Feb. 9, 2016,entitled SURGICAL INSTRUMENT ARTICULATION MECHANISM WITH SLOTTEDSECONDARY CONSTRAINT, the entire disclosure of which is herebyincorporated by reference herein. As can be seen in FIG. 7, theinterchangeable surgical tool assembly 1000 can further include aproximal housing or nozzle 1300 comprised of nozzle portions 1302, 1304as well as an actuator wheel portion 1306 that is configured to becoupled to the assembled nozzle portions 1302, 1304 by snaps, lugs,and/or screws, for example. The interchangeable surgical tool assembly1000 can further include a closure tube assembly 1400 which can beutilized to close and/or open the anvil 1130 of the end effector 1100 aswill be discussed in further detail below. Primarily referring now toFIGS. 8 and 9, the interchangeable surgical tool assembly 1000 caninclude a spine assembly 1500 which can be configured to support thearticulation lock 1210. The spine assembly 1500 comprises an “elastic”spine or frame member 1510 which will be described in further detailbelow. A distal end portion 1522 of the elastic spine member 1510 isattached to a distal frame segment 1560 that operably supports thearticulation lock 1210 therein. As can be seen in FIGS. 7 and 8, thespine assembly 1500 is configured to, one, slidably support a firingmember assembly 1600 therein and, two, slidably support the closure tubeassembly 1400 which extends around the spine assembly 1500. The spineassembly 1500 can also be configured to slidably support a proximalarticulation driver 1700.

As can be seen in FIG. 10, the distal frame segment 1560 is pivotallycoupled to the elongate channel 1102 by an end effector mountingassembly 1230. In one arrangement, the distal end 1562 of the distalframe segment 1560 has a pivot pin 1564 formed thereon, for example. Thepivot pin 1564 is adapted to be pivotally received within a pivot hole1234 formed in pivot base portion 1232 of the end effector mountingassembly 1230. The end effector mounting assembly 1230 is attached tothe proximal end 1103 of the elongate channel 1102 by a spring pin 1108or other suitable member. The pivot pin 1564 defines an articulationaxis B-B that is transverse to the shaft axis SA. See FIG. 4. Such anarrangement facilitates pivotal travel (i.e., articulation) of the endeffector 1100 about the articulation axis B-B relative to the spineassembly 1500.

Still referring to FIG. 10, the articulation driver 1700 has a distalend 1702 that is configured to operably engage the articulation lock1210. The articulation lock 1210 includes an articulation frame 1212that is adapted to operably engage a drive pin 1238 on the pivot baseportion 1232 of the end effector mounting assembly 1230. In addition, across-link 1237 may be linked to the drive pin 1238 and articulationframe 1212 to assist articulation of the end effector 1100. As indicatedabove, further details regarding the operation of the articulation lock1210 and the articulation frame 1212 may be found in U.S. patentapplication Ser. No. 13/803,086, now U.S. Patent Application PublicationNo. 2014/0263541. Further details regarding the end effector mountingassembly and a crosslink may be found in U.S. patent application Ser.No. 15/019,245, filed Feb. 9, 2016, entitled SURGICAL INSTRUMENTS WITHCLOSURE STROKE REDUCTION ARRANGEMENTS, the entire disclosure of which ishereby incorporated by reference herein. In various circumstances, theelastic spine member 1510 includes a proximal end 1514 which isrotatably supported in a chassis 1800. In one arrangement, the proximalend 1514 of the elastic spine member 1510 has a thread 1516 formedthereon for threaded attachment to a spine bearing that is configured tobe supported within the chassis 1800, for example. Such an arrangementfacilitates rotatable attachment of the elastic spine member 1510 to thechassis 1800 such that the spine assembly 1500 may be selectivelyrotated about a shaft axis SA relative to the chassis 1800.

Referring primarily to FIG. 7, the interchangeable surgical toolassembly 1000 includes a closure shuttle 1420 that is slidably supportedwithin the chassis 1800 such that the closure shuttle 1420 may beaxially moved relative to the chassis 1800. In one form, the closureshuttle 1420 includes a pair of proximally-protruding hooks 1421 thatare configured to be attached to the attachment pin 516 that is attachedto the closure linkage assembly 514 of the handle assembly 500 as wasdiscussed above. A proximal end 1412 of a proximal closure tube segment1410 is rotatably coupled to the closure shuttle 1420. For example, aU-shaped connector 1424 is inserted into an annular slot 1414 in theproximal end 1412 of the proximal closure tube segment 1410 and isretained within vertical slots 1422 in the closure shuttle 1420. SeeFIG. 7. Such an arrangement serves to attach the proximal closure tubesegment 1410 to the closure shuttle 1420 for axial travel therewithwhile enabling the closure tube assembly 1400 to rotate relative to theclosure shuttle 1420 about the shaft axis SA. A closure spring isjournaled on the proximal end 1412 of the proximal closure tube segment1410 and serves to bias the closure tube assembly 1400 in the proximaldirection PD which can serve to pivot the closure trigger 512 on thehandle assembly 500 (FIG. 3) into the unactuated position when theinterchangeable surgical tool assembly 1000 is operably coupled to thehandle assembly 500.

As indicated above, the illustrated interchangeable surgical toolassembly 1000 includes an articulation joint 1200. Other interchangeablesurgical tool assemblies, however, may not be capable of articulation.As can be seen in FIG. 10, upper and lower tangs 1415, 1416 protrudedistally from a distal end of the proximal closure tube segment 1410which are configured to be movably coupled to an end effector closuresleeve or distal closure tube segment 1430 of the closure tube assembly1400. As can be seen in FIG. 10, the distal closure tube segment 1430includes upper and lower tangs 1434, 1436 that protrude proximally froma proximal end thereof. An upper double pivot link 1220 includesproximal and distal pins that engage corresponding holes in the uppertangs 1415, 1434 of the proximal closure tube segment 1410 and distalclosure tube segment 1430, respectively. Similarly, a lower double pivotlink 1222 includes proximal and distal pins that engage correspondingholes in the lower tangs 1416 and 1436 of the proximal closure tubesegment 1410 and distal closure tube segment 1430, respectively. As willbe discussed in further detail below, distal and proximal axialtranslation of the closure tube assembly 1400 will result in the closingand opening of the anvil 1130 relative to the elongate channel 1102.

As mentioned above, the interchangeable surgical tool assembly 1000further includes a firing member assembly 1600 that is supported foraxial travel within the spine assembly 1500. The firing member assembly1600 includes an intermediate firing shaft portion 1602 that isconfigured to be attached to a distal cutting portion or knife bar 1610.The firing member assembly 1600 may also be referred to herein as a“second shaft” and/or a “second shaft assembly”. As can be seen in FIGS.7-10, the intermediate firing shaft portion 1602 may include alongitudinal slot 1604 in the distal end thereof which can be configuredto receive a tab on the proximal end of the knife bar 1610. Thelongitudinal slot 1604 and the proximal end of the knife bar 1610 can besized and configured to permit relative movement therebetween and cancomprise a slip joint 1612. The slip joint 1612 can permit theintermediate firing shaft portion 1602 of the firing member assembly1600 to be moved to articulate the end effector 1100 without moving, orat least substantially moving, the knife bar 1610. Once the end effector1100 has been suitably oriented, the intermediate firing shaft portion1602 can be advanced distally until a proximal sidewall of thelongitudinal slot 1604 comes into contact with the tab on the knife bar1610 to advance the knife bar 1610 and fire the staple cartridge 1110positioned within the elongate channel 1102. As can be further seen inFIGS. 8 and 9, the elastic spine member 1520 has an elongate opening orwindow 1525 therein to facilitate the assembly and insertion of theintermediate firing shaft portion 1602 into the elastic spine member1520. Once the intermediate firing shaft portion 1602 has been insertedtherein, a top frame segment 1527 may be engaged with the elastic spinemember 1520 to enclose the intermediate firing shaft portion 1602 andknife bar 1610 therein. Further description of the operation of thefiring member assembly 1600 may be found in U.S. patent application Ser.No. 13/803,086, now U.S. Patent Application Publication No.2014/0263541.

Further to the above, the interchangeable tool assembly 1000 can includea clutch assembly 1620 which can be configured to selectively andreleasably couple the articulation driver 1700 to the firing memberassembly 1600. In one form, the clutch assembly 1620 includes a lockcollar, or sleeve 1622, positioned around the firing member assembly1600 wherein the lock sleeve 1622 can be rotated between an engagedposition in which the lock sleeve 1622 couples the articulation driver1700 to the firing member assembly 1600 and a disengaged position inwhich the articulation driver 1700 is not operably coupled to the firingmember assembly 1600. When the lock sleeve 1622 is in its engagedposition, distal movement of the firing member assembly 1600 can movethe articulation driver 1700 distally and, correspondingly, proximalmovement of the firing member assembly 1600 can move the articulationdriver 1700 proximally. When the lock sleeve 1622 is in its disengagedposition, movement of the firing member assembly 1600 is not transmittedto the articulation driver 1700 and, as a result, the firing memberassembly 1600 can move independently of the articulation driver 1700. Invarious circumstances, the articulation driver 1700 can be held inposition by the articulation lock 1210 when the articulation driver 1700is not being moved in the proximal or distal directions by the firingmember assembly 1600.

Referring primarily to FIG. 7, the lock sleeve 1622 can comprise acylindrical, or an at least substantially cylindrical, body including alongitudinal aperture 1624 defined therein configured to receive thefiring member assembly 1600. The lock sleeve 1622 can comprisediametrically-opposed, inwardly-facing lock protrusions 1626, 1628 andan outwardly-facing lock member 1629. The lock protrusions 1626, 1628can be configured to be selectively engaged with the intermediate firingshaft portion 1602 of the firing member assembly 1600. Moreparticularly, when the lock sleeve 1622 is in its engaged position, thelock protrusions 1626, 1628 are positioned within a drive notch 1605defined in the intermediate firing shaft portion 1602 such that a distalpushing force and/or a proximal pulling force can be transmitted fromthe firing member assembly 1600 to the lock sleeve 1622. When the locksleeve 1622 is in its engaged position, the second lock member 1629 isreceived within a drive notch 1704 defined in the articulation driver1700 such that the distal pushing force and/or the proximal pullingforce applied to the lock sleeve 1622 can be transmitted to thearticulation driver 1700. In effect, the firing member assembly 1600,the lock sleeve 1622, and the articulation driver 1700 will movetogether when the lock sleeve 1622 is in its engaged position. On theother hand, when the lock sleeve 1622 is in its disengaged position, thelock protrusions 1626, 1628 may not be positioned within the drive notch1605 of the intermediate firing shaft portion 1602 of the firing memberassembly 1600 and, as a result, a distal pushing force and/or a proximalpulling force may not be transmitted from the firing member assembly1600 to the lock sleeve 1622. Correspondingly, the distal pushing forceand/or the proximal pulling force may not be transmitted to thearticulation driver 1700. In such circumstances, the firing memberassembly 1600 can be slid proximally and/or distally relative to thelock sleeve 1622 and the proximal articulation driver 1700. Theclutching assembly 1620 further includes a switch drum 1630 thatinterfaces with the lock sleeve 1622. Further details concerning theoperation of the switch drum and lock sleeve 1622 may be found in U.S.patent application Ser. No. 13/803,086, now U.S. Patent ApplicationPublication No. 2014/0263541, and Ser. No. 15/019,196. The switch drum1630 can further comprise at least partially circumferential openings1632, 1634 defined therein which can receive circumferential mounts 1305that extend from the nozzle halves 1302, 1304 and permit relativerotation, but not translation, between the switch drum 1630 and theproximal nozzle 1300. See FIG. 6. Rotation of the nozzle 1300 to a pointwhere the mounts reach the end of their respective slots 1632, 1634 inthe switch drum 1630 will result in rotation of the switch drum 1630about the shaft axis SA. Rotation of the switch drum 1630 willultimately result in the movement of the lock sleeve 1622 between itsengaged and disengaged positions. Thus, in essence, the nozzle 1300 maybe employed to operably engage and disengage the articulation drivesystem with the firing drive system in the various manners described infurther detail in U.S. patent application Ser. No. 13/803,086, now U.S.Patent Application Publication No. 2014/0263541, and U.S. patentapplication Ser. No. 15/019,196, which have each been hereinincorporated by reference in their respective entirety.

In the illustrated arrangement, the switch drum 1630 includes a anL-shaped slot 1636 that extends into a distal opening 1637 in the switchdrum 1630. The distal opening 1637 receives a transverse pin 1639 of ashifter plate 1638. In one example, the shifter plate 1638 is receivedwithin a longitudinal slot that is provided in the lock sleeve 1622 tofacilitate the axial movement of the lock sleeve 1622 when engaged withthe articulation driver 1700. Further details regarding the operation ofthe shifter plate and shift drum arrangements may be found in U.S.patent application Ser. No. 14/868,718, filed Sep. 28, 2015, entitledSURGICAL STAPLING INSTRUMENT WITH SHAFT RELEASE, POWERED FIRING ANDPOWERED ARTICULATION, now U.S. Patent Application Publication No.2017/0086823, the entire disclosure of which is hereby incorporated byreference herein.

As also illustrated in FIGS. 7 and 8, the interchangeable tool assembly1000 can comprise a slip ring assembly 1640 which can be configured toconduct electrical power to and/or from the end effector 1100, and/orcommunicate signals to and/or from the end effector 1100, back to amicroprocessor in the handle assembly or robotic system controller, forexample. Further details concerning the slip ring assembly 1640 andassociated connectors may be found in U.S. patent application Ser. No.13/803,086, now U.S. Patent Application Publication No. 2014/0263541,and U.S. patent application Ser. No. 15/019,196 which have each beenherein incorporated by reference in their respective entirety as well asin U.S. patent application Ser. No. 13/800,067, entitled STAPLECARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, now U.S. Patent ApplicationPublication No. 2014/0263552, which is hereby incorporated by referenceherein in its entirety. As also described in further detail in theaforementioned patent applications that have been incorporated byreference herein, the interchangeable surgical tool assembly 1000 canalso comprise at least one sensor that is configured to detect theposition of the switch drum 1630.

Referring again to FIG. 7, the chassis 1800 includes one or more taperedattachment portions 1802 formed thereon that are adapted to be receivedwithin corresponding dovetail slots 507 formed within the distal endportion of the frame 506 of the handle assembly 500 as was discussedabove. As can be further seen in FIG. 7, a shaft attachment lug 1605 isformed on the proximal end of the intermediate firing shaft 1602. Aswill be discussed in further detail below, the shaft attachment lug 1605is received in a firing shaft attachment cradle 542 that is formed inthe distal end of the longitudinal drive member 540 when theinterchangeable surgical tool assembly 1000 is coupled to the handleassembly 500. See FIG. 3.

Various interchangeable surgical tool assemblies employ a latch system1810 for removably coupling the interchangeable surgical tool assembly1000 to the frame 506 of the handle assembly 500. In at least one form,as can be seen in FIG. 7, the latch system 1810 includes a lock memberor lock yoke 1812 that is movably coupled to the chassis 1800. The lockyoke 1812 has a U-shape with two spaced downwardly extending legs 1814.The legs 1814 each have a pivot lug formed thereon that are adapted tobe received in corresponding holes 1816 formed in the chassis 1800. Suchan arrangement facilitates the pivotal attachment of the lock yoke 1812to the chassis 1800. The lock yoke 1812 may include two proximallyprotruding lock lugs 1818 that are configured for releasable engagementwith corresponding lock detents or grooves 509 in the distal end of theframe 506 of the handle assembly 500. See FIG. 3. In various forms, thelock yoke 1812 is biased in the proximal direction by a spring orbiasing member 1819. Actuation of the lock yoke 1812 may be accomplishedby a latch button 1820 that is slidably mounted on a latch actuatorassembly 1822 that is mounted to the chassis 1800. The latch button 1820may be biased in a proximal direction relative to the lock yoke 1812.The lock yoke 1812 may be moved to an unlocked position by biasing thelatch button 1820 the in distal direction which also causes the lockyoke 1812 to pivot out of retaining engagement with the distal end ofthe frame 506. When the lock yoke 1812 is in retaining engagement withthe distal end of the frame 506, the lock lugs 1818 are retaininglyseated within the corresponding lock detents or grooves 509 in thedistal end of the frame 506.

In the illustrated arrangement, the lock yoke 1812 includes at least oneand preferably two lock hooks 1824 that are adapted to contactcorresponding lock lug portions 1426 that are formed on the closureshuttle 1420. When the closure shuttle 1420 is in an unactuatedposition, the lock yoke 1812 may be pivoted in a distal direction tounlock the interchangeable surgical tool assembly 1000 from the handleassembly 500. When in that position, the lock hooks 1824 do not contactthe lock lug portions 1426 on the closure shuttle 1420. However, whenthe closure shuttle 1420 is moved to an actuated position, the lock yoke1812 is prevented from being pivoted to an unlocked position. Statedanother way, if the clinician were to attempt to pivot the lock yoke1812 to an unlocked position or, for example, the lock yoke 1812 was inadvertently bumped or contacted in a manner that might otherwise causeit to pivot distally, the lock hooks 1824 on the lock yoke 1812 willcontact the lock lugs 1426 on the closure shuttle 1420 and preventmovement of the lock yoke 1812 to an unlocked position.

Still referring to FIG. 10, the knife bar 1610 may comprise a laminatedbeam structure that includes at least two beam layers. Such beam layersmay comprise, for example, stainless steel bands that are interconnectedby, for example, welds and/or pins at their proximal ends and/or atother locations along the length of the bands. In alternativeembodiments, the distal ends of the bands are not connected together toallow the laminates or bands to splay relative to each other when theend effector is articulated. Such an arrangement permits the knife bar1610 to be sufficiently flexible to accommodate articulation of the endeffector. Various laminated knife bar arrangements are disclosed in U.S.patent application Ser. No. 15/019,245. As can also be seen in FIG. 10,a middle support member 1614 is employed to provide lateral support tothe knife bar 1610 as it flexes to accommodate articulation of thesurgical end effector 1100. Further details concerning the middlesupport member and alternative knife bar support arrangements aredisclosed in U.S. patent application Ser. No. 15/019,245. As can also beseen in FIG. 10, a firing member or knife member 1620 is attached to thedistal end of the knife bar 1610.

FIG. 11 illustrates one form of a firing member 1660 that may beemployed with the interchangeable tool assembly 1000. The firing member1660 comprises a body portion 1662 that includes a proximally extendingconnector member 1663 that is configured to be received in acorrespondingly shaped connector opening 1614 in the distal end of theknife bar 1610. See FIG. 10. The connector 1663 may be retained withinthe connector opening 1614 by friction, welding, and/or a suitableadhesive, for example. Referring to FIGS. 15-17, the body portion 1662protrudes through an elongate slot 1104 in the elongate channel 1102 andterminates in a foot member 1664 that extends laterally on each side ofthe body portion 1662. As the firing member 1660 is driven distallythrough the surgical staple cartridge 1110, the foot member 1664 rideswithin a passage in the elongate channel 1102 that is located under thesurgical staple cartridge 1110. As can be seen in FIG. 11, the firingmember 1660 may further include laterally protruding central tabs, pins,or retainer features 1680. As the firing member 1660 is driven distallythrough the surgical staple cartridge 1110, the central retainerfeatures 1680 ride on the inner surface 1106 of the elongate channel1102. The body portion 1662 of the firing member 1660 further includes atissue cutting edge or feature 1666 that is disposed between a distallyprotruding shoulder 1665 and a distally protruding top nose portion1670. As can be further seen in FIG. 11, the firing member 1660 mayfurther include two laterally extending top tabs, pins or anvilengagement features 1665. See FIGS. 13 and 14. As the firing member 1660is driven distally, a top portion of the body 1662 extends through acentrally disposed anvil slot 1138 (FIG. 14) and the top anvilengagement features 1672 ride on corresponding ledges 1136 formed oneach side of the anvil slot 1134.

Returning to FIG. 10, the firing member 1660 is configured to operablyinterface with a sled 1120 that is supported within the body 1111 of thesurgical staple cartridge 1110. The sled 1120 is slidably displaceablewithin the surgical staple cartridge body 1111 from a proximal startingposition adjacent the proximal end 1112 of the cartridge body 1111 to anending position adjacent a distal end 1113 of the cartridge body 1111.The cartridge body 1111 operably supports therein a plurality of stapledrivers (not shown in FIG. 10) that are aligned in rows on each side ofa centrally disposed slot 1114. The centrally disposed slot 1114 enablesthe firing member 1660 to pass therethrough and cut the tissue that isclamped between the anvil 1130 and the staple cartridge 1110. Thedrivers are associated with corresponding pockets 1115 that open throughthe upper deck surface of the cartridge body. Each of the staple driverssupports one or more surgical staples or fasteners thereon. The sled1120 includes a plurality of sloped or wedge-shaped cams 1122 whereineach cam 1122 corresponds to a particular line of fasteners or driverslocated on a side of the slot 1114. In the illustrated example, one cam1122 is aligned with one line of “double” drivers that each support twostaples or fasteners thereon and another cam 1122 is aligned withanother line of “single” drivers on the same side of the slot 1114 thateach support a single surgical staple or fastener thereon. Thus, in theillustrated example, when the surgical staple cartridge 1110 is “fired”,there will be three lines of staples on each lateral side of the tissuecut line. However, other cartridge and driver configurations could alsobe employed to fire other staple/fastener arrangements. The sled 1120has a central body portion 1124 that is configured to be engaged by theshoulder 1665 of the firing member 1660. When the firing member 1660 isfired or driven distally, the firing member 1660 drives the sled 1120distally as well. As the firing member 1660 moves distally through thecartridge 1110, the tissue cutting feature 1666 cuts the tissue that isclamped between the anvil assembly 1130 and the cartridge 1110 and,also, the sled 1120 drives the drivers upwardly in the cartridge whichdrive the corresponding staples or fasteners into forming contact withthe anvil assembly 1130.

In embodiments where the firing member includes a tissue cuttingsurface, it may be desirable for the elongate shaft assembly to beconfigured in such a way so as to prevent the inadvertent advancement ofthe firing member unless an unspent staple cartridge is properlysupported in the elongate channel 1102 of the surgical end effector1100. If, for example, no staple cartridge is present at all and thefiring member is distally advanced through the end effector, the tissuewould be severed, but not stapled. Similarly, if a spent staplecartridge (i.e., a staple cartridge wherein at least some of the stapleshave already been fired therefrom) is present in the end effector andthe firing member is advanced, the tissue would be severed, but may notbe completely stapled, if at all. It will be appreciated that suchoccurrences could lead to undesirable results during the surgicalprocedure. U.S. Pat. No. 6,988,649 entitled SURGICAL STAPLING INSTRUMENTHAVING A SPENT CARTRIDGE LOCKOUT, U.S. Pat. No. 7,044,352 entitledSURGICAL STAPLING INSTRUMENT HAVING A SINGLE LOCKOUT MECHANISM FORPREVENTION OF FIRING, and U.S. Pat. No. 7,380,695 entitled SURGICALSTAPLING INSTRUMENT HAVING A SINGLE LOCKOUT MECHANISM FOR PREVENTION OFFIRING, and U.S. patent application Ser. No. 14/742,933, entitledSURGICAL STAPLING INSTRUMENTS WITH LOCKOUT ARRANGEMENTS FOR PREVENTINGFIRING SYSTEM ACTUATION WHEN A CARTRIDGE IS SPENT OR MISSING eachdisclose various firing member lockout arrangements. Each of thosereferences is hereby incorporated by reference in its entirety herein.

An “unfired”, “unspent”, “fresh” or “new” fastener cartridge 1110 meansthat the fastener cartridge 1110 has all of its fasteners in their“ready-to-be-fired positions”. The new cartridge 1110 is seated withinthe elongate channel 1102 and may be retained therein by snap featureson the cartridge body that are configured to retainingly engagecorresponding portions of the elongate channel 1102. FIGS. 15 and 18illustrate a portion of the surgical end effector 1100 with a new orunfired surgical staple cartridge 1110 seated therein. As can be seen inFIGS. 15 and 18, the sled 1120 is in its starting position. To preventthe firing system from being activated and, more precisely, to preventthe firing member 1660 from being distally driven through the endeffector 1110 unless an unfired or new surgical staple cartridge hasbeen properly seated within the elongate channel 1102, theinterchangeable surgical tool assembly 1000 employs a firing memberlockout system generally designated as 1650.

Referring now to FIGS. 10 and 15-19, the firing member lockout system1650 includes a movable lock member 1652 that is configured toretainingly engage the firing member 1660 when a new surgical staplecartridge 1110 is not seated properly within the elongate channel 1102.More specifically, the lock member 1652 comprises at least one laterallymoving locking portion 1654 that is configured to retainingly engage acorresponding portion of the firing member 1660 when the sled 1120 isnot present within the cartridge 1110 in its starting position. In fact,the lock member 1652 employs two laterally moving locking portions 1654which each engage a laterally extending portion of the firing member1660. Other lockout arrangements can be used.

The lock member 1652 comprises a generally U-shaped spring member whereeach laterally movable leg or locking portion 1654 extends from acentral spring portion 1653 and is configured to move in lateraldirections represented by “L” in FIGS. 18 and 19. It will be appreciatedthat the term “lateral directions” refers to directions that aretransverse to the shaft axis SA (FIG. 2). The spring or lock member 1652may be fabricated from high strength spring steel and/or a similarmaterial, for example. The central spring portion 1653 is seated withina slot 1236 in the end effector mounting assembly 1230. See FIG. 10. Ascan be seen in FIGS. 15-17, each of the laterally movable legs orlocking portions 1654 has a distal end 1656 with a locking window 1658therein. When the locking member 1652 is in a locked position, thecentral retainer feature 1680 on each lateral side of the firing member1660 extends into corresponding locking windows 1658 defined in thelocking portions 1654 to retainingly prevent the firing member frombeing distally, or axially, advanced.

Operation of the firing member lock out system will be explained withreference to FIGS. 15-19. FIGS. 15 and 18 illustrate a portion of thesurgical end effector 1100 with a new unfired cartridge 1110 properlyinstalled therein. As can be seen in FIGS. 15 and 18, the sled 1120includes an unlocking feature 1126 that corresponds to each of thelaterally movable locking portions 1654. An unlocking feature 1126 isprovided on or extends proximally from each of the central wedge-shapedcams 1122. In alternative arrangements, the unlocking feature 1126 maycomprise a proximally protruding portion of the correspondingwedge-shaped cam 1122. As can be seen in FIG. 18, the unlocking features1124 engage and bias the corresponding locking portions 1654 laterallyin a direction that is transverse to the shaft axis SA (FIG. 2) when thesled 1120 is in its starting position. When the locking portions 1654are in such unlocked orientations, the central retainer features 1680are not in retaining engagement with the locking windows 1658. In suchinstances, the firing member 1660 may be distally, or axially, advanced(fired). However, when a cartridge is not present in the elongatechannel 1102 or the sled 1120 has been moved out of its startingposition (meaning the cartridge is partially or completely fired), thelocking portions 1654 spring laterally into retaining engagement withthe firing member 1660. In such instances, referring to FIG. 19, thefiring member 1660 cannot be moved distally.

FIGS. 16 and 17 illustrate the retraction of the firing member 1660 backto its starting, or unfired, position after performing a staple firingstroke as discussed above. FIG. 16 depicts the initial reengagement ofthe retaining features 1680 into their corresponding locking windows1658. FIG. 17 illustrates the retaining feature in its locked positionwhen the firing member 1660 has been fully retracted back to itsstarting position. To assist in the lateral displacement of the lockingportions 1654 when they are contacted by the proximally moving retainingfeatures 1680, each of the retaining features 1680 may be provided witha proximally-facing, laterally-tapered end portion. Such a lockoutsystem prevents the actuation of the firing member 1660 when a newunfired cartridge is not present or when a new unfired cartridge ispresent, but has not been properly seated in the elongate channel 1102.In addition, the lockout system may prevent the clinician from distallyadvancing the firing member in the case where a spent or partially firedcartridge has been inadvertently properly seated within the elongatechannel. Another advantage that may be provided by the lockout system1650 is that, unlike other firing member lock out arrangements thatrequire movement of the firing member into and out of alignment with thecorresponding slots/passages in the staple cartridge, the firing member1660 remains in alignment with the cartridge passages while in thelocked and unlocked positions. The locking portions 1654 are designed tomove laterally into and out of engagement with corresponding sides ofthe firing member. Such lateral movement of the locking portions orportion is distinguishable from other locking arrangements that move invertical directions to engage and disengage portions of the firingmember.

Returning to FIGS. 13 and 14, the anvil 1130 includes an elongate anvilbody portion 1132 and a proximal anvil mounting portion 1150. Theelongate anvil body portion 1132 includes an outer surface 1134 thatdefines two downwardly extending tissue stop members 1136 that areadjacent to the proximal anvil mounting portion 1150. The elongate anvilbody portion 1132 also includes an underside 1135 that defines anelongate anvil slot 1138. In the illustrated arrangement shown in FIG.14, the anvil slot 1138 is centrally disposed in the underside 1135. Theunderside 1135 includes three rows 1140, 1141, 1142 of staple formingpockets 1143, 1144 and 1145 located on each side of the anvil slot 1138.Adjacent each side of the anvil slot 1138 are two elongate anvilpassages 1146. Each passage 1146 has a proximal ramp portion 1148. SeeFIG. 13. As the firing member 1660 is advanced distally, the top anvilengagement features 1632 initially enter the corresponding proximal rampportions 1148 and into the corresponding elongate anvil passages 1146.

Turning to FIGS. 12 and 13, the anvil slot 1138, as well as the proximalramp portion 1148, extend into the anvil mounting portion 1150. Statedanother way, the anvil slot 1138 divides or bifurcates the anvilmounting portion 1150 into two anvil attachment flanges 1151. The anvilattachments flanges 1151 are coupled together at their proximal ends bya connection bridge 1153. The connection bridge 1153 supports the anvilattachment flanges 1151 and can serve to make the anvil mounting portion1150 more rigid than the mounting portions of other anvil arrangementswhich are not connected at their proximal ends. As can also be seen inFIGS. 12 and 14, the anvil slot 1138 has a wide portion 1139 toaccommodate the top portion including the top anvil engagement features1632, of the firing member 1660 when the firing member 1660 is in itsproximal unfired position.

As can be seen in FIGS. 13 and 20-24, each of the anvil attachmentflanges 1151 includes a transverse mounting hole 1156 that is configuredto receive a pivot pin 1158 (FIGS. 10 and 20) therethrough. The anvilmounting portion 1150 is pivotally pinned to the proximal end 1103 ofthe elongate channel 1102 by the pivot pin 1158 which extends throughmounting holes 1107 in the proximal end 1103 of the elongate channel1102 and the mounting hole 1156 in anvil mounting portion 1150. Such anarrangement pivotally affixes the anvil 1130 to the elongate channel1102 s that the anvil 1130 can be pivoted about a fixed anvil axis A-Awhich is transverse to the shaft axis SA. See FIG. 5. The anvil mountingportion 1150 also includes a cam surface 1152 that extends from acentralized firing member parking area 1154 to the outer surface 1134 ofthe anvil body portion 1132.

Further to the above, the anvil 1130 is movable between an open positionand closed positions by axially advancing and retracting the distalclosure tube segment 1430, as discussed further below. A distal endportion of the distal closure tube segment 1430 has an internal camsurface formed thereon that is configured to engage the cam surface1552, or cam surfaces formed on the anvil mounting portion 1150, andmove the anvil 1130. FIG. 22 illustrates a cam surface 1152 a formed onthe anvil mounting portion 1150 so as to establish a single contact path1155 a with the internal cam surface 1444, for example, on the distalclosure tube segment 1430. FIG. 23 illustrates a cam surface 1152 b thatis configured relative to the internal cam surface 1444 on the distalclosure tube segment to establish two separate and distinct arcuatecontact paths 1155 b between the cam surface 1152 on the anvil mountingportion 1150 and internal cam surface 1444 on the distal closure tubesegment 1430. In addition to other potential advantages discussedherein, such an arrangement may better distribute the closure forcesfrom the distal closure tube segment 1430 to the anvil 1130. FIG. 24illustrates a cam surface 1152 c that is configured relative to theinternal cam surface 1444 of the distal closure tube segment 1430 toestablish three distinct zones of contact 1155 c and 1155 d between thecam surfaces on the anvil mounting portion 1150 and the distal closuretube segment 1430. The zones 1155 c, 1155 d establish larger areas ofcamming contact between the cam surface or cam surfaces on the distalclosure tube segment 1430 and the anvil mounting portion 1150 and maybetter distribute the closure forces to the anvil 1130.

As the distal closure tube segment 1430 cammingly engages the anvilmounting portion 1150 of the anvil 1130, the anvil 1130 is pivoted aboutthe anvil axis AA (FIG. 5) which results in the pivotal movement of thedistal end of the end 1133 of elongate anvil body portion 1132 towardthe surgical staple cartridge 1110 and the distal end 1105 of theelongate channel 1102. As the anvil body portion 1132 begins to pivot,it contacts the tissue that is to be cut and stapled which is nowpositioned between the underside 1135 of the elongate anvil body portion1132 and the deck 1116 of the surgical staple cartridge 1110. As theanvil body portion 1132 is compressed onto the tissue, the anvil 1130may experience considerable amounts of resistive forces and/or bendingloads, for example. These resistive forces are overcome as the distalclosure tube 1430 continues its distal advancement. However, dependingupon their magnitudes and points of application to the anvil bodyportion 1132, these resistive forces could tend to cause portions of theanvil 1130 to flex away from the staple cartridge 1110 which maygenerally be undesirable. For example, such flexure may causemisalignment between the firing member 1660 and the passages 1148, 1146within the anvil 1130. In instances wherein the flexure is excessive,such flexure could significantly increase the amount of firing forcerequired to fire the instrument (i.e., drive the firing member 1660through the tissue from its starting to ending position). Such excessivefiring force may result in damage to the end effector, the firingmember, the knife bar, and/or the firing drive system components, forexample. Thus, it may be advantageous for the anvil to be constructed soas to resist such flexure.

FIGS. 25-27 illustrate an anvil 1130′ that includes features thatimprove the stiffness of the anvil body and its resistance to flexureforces that may be generated during the closing and/or firing processes.The anvil 1130′ may otherwise be identical in construction to the anvil1130 described above except for the differences discussed herein. As canbe seen in FIGS. 25-27, the anvil 1130′ has an elongate anvil body 1132′that has an upper body portion 1165 that and anvil cap 1170 attachedthereto. The anvil cap 1170 is roughly rectangular in shape and has anouter cap perimeter 1172, although the anvil cap 1170 can have anysuitable shape. The perimeter 1172 of the anvil cap 1170 is configuredto be inserted into a correspondingly-shaped opening 1137 formed in theupper body portion 1165 and positioned against axially extendinginternal ledge portions 1139 formed therein. See FIG. 27. The internalledge portions 1139 are configured to support the corresponding longsides 1177 of the anvil cap 1170. In an alternative embodiment, theanvil cap 1170 may be slid onto the internal ledges 1139 through anopening in the distal end 1133 of the anvil body 1132′. In yet anotherembodiment, no internal ledge portions are provided. The anvil body1132′ and the anvil cap 1170 may be fabricated from suitable metal thatis conducive to welding. A first weld 1178 may extend around the entirecap perimeter 1172 of the anvil cap 1170 or it may only be located alongthe long sides 1177 of the anvil cap 1170 and not the distal end 1173and/or proximal end 1175 thereof. The first weld 1178 may be continuousor it may be discontinuous or intermittent. In those embodiments wherethe first weld 1178 is discontinuous or intermittent, the weld segmentsmay be equally distributed along the long sides 1177 of the anvil cap1170, more densely spaced closer to the distal ends of the long sides1177, and/or more densely spaced closer to the proximal ends of the longsides 1177. In certain arrangements, the weld segments may be moredensely spaced in the center areas of the long sides 1177 of the anvilcap 1170.

FIGS. 28-30 illustrate an anvil cap 1170′ that is configured to bemechanically interlocked to the anvil body 1132′ as well as welded tothe upper body portion 1165. In this embodiment, a plurality ofretention formations 1182 are defined in the wall 1180 of the upper bodyportion 1165 that defines opening 1137. As used in this context, theterm “mechanically interlocked” means that the anvil cap will remainaffixed to the elongate anvil body regardless of the orientation of theelongate anvil body and without any additional retaining or fasteningsuch as welding and/or adhesive, for example. The retention formations1182 may protrude inwardly into the opening 1137 from the opening wall1180, although any suitable arrangement can be used. The retentionformations 1182 may be integrally formed into the wall 1180 or otherwisebe attached thereto. The retention formations 1182 are designed tofrictionally engage a corresponding portion of the anvil cap 1170′ whenthe anvil cap 1170′ is installed in the opening 1137 to frictionallyretain the anvil cap 1170′ therein. The retention formations 1182protrude inwardly into the opening 1137 and are configured to befrictionally received within a correspondingly shaped engagement area1184 formed in the outer perimeter 1172′ of the anvil cap 1170′. Theretention formations 1182 only correspond to the long sides 1177′ of theanvil cap 1170′ and are not provided in the portions of the wall 1180that correspond to the distal end 1173 or proximal end 1175 of the anvilcap 1170′. In alternative arrangements, the retention formations 1182may also be provided in the portions of the wall 1180 that correspond tothe distal end 1173 and proximal end 1175 of the anvil cap 1170′ as wellas the long sides 1177′ thereof. In still other arrangements, theretention formations 1182 may only be provided in the portions of thewall 1180 that correspond to one or both of the distal and proximal ends1173, 1175 of the anvil cap 1170′. In still other arrangements, theretention formations 1182 may be provided in the portions of the wall1180 corresponding to the long sides 1177′ and only one of the proximaland distal ends 1173, 1175 of the anvil cap 1170′. It will be furtherunderstood that the retention protrusions in all of the foregoingembodiments may be alternatively formed on the anvil cap with theengagement areas being formed in the elongate anvil body.

In the embodiment illustrated in FIGS. 28-30, the retention formations1182 are equally spaced or equally distributed along the wall portions1180 of the anvil cap 1170′. In alternative embodiments, the retentionformations 1182 may be more densely spaced closer to the distal ends ofthe long sides 1177′ or more densely spaced closer to the proximal endsof the long sides 1177′. Stated another way, the spacing between thoseretention formations adjacent the distal end, the proximal end or boththe distal and proximal ends may be less than the spacing of theformations located in the central portion of the anvil cap 1170′. Instill other arrangements, the retention formations 1182 may be moredensely spaced in the center areas of the long sides 1177′ of the anvilcap 1170′. In some alternative embodiments, the correspondingly shapedengagement areas 1184 may not be provided in the outer perimeter 1172′or in portions of the outer perimeter 1172′ of the anvil cap 1170′. Inother embodiments, the retention formations and correspondingly-shapedengagement areas may be provided with different shapes and sizes. Inalternative arrangements, the retention formations may be sized relativeto the engagement areas so that there is no interference fittherebetween. In such arrangements, the anvil cap may be retained inposition by welding, and/or an adhesive, for example.

In the illustrated example, a weld 1178′ extends around the entireperimeter 1172′ of the anvil cap 1170′. Alternatively, the weld 1178′ islocated along the long sides 1177′ of the anvil cap 1170′ and not thedistal end 1173 and/or proximal end 1175 thereof. The weld 1178′ may becontinuous or it may be discontinuous or intermittent. In thoseembodiments where the weld 1178′ is discontinuous or intermittent, theweld segments may be equally distributed along the long sides 1177′ ofthe anvil cap 1170′ or the weld segments may be more densely spacedcloser to the distal ends of the long sides 1177′ or more densely spacedcloser to the proximal ends of the long sides 1177′. In still otherarrangements, the weld segments may be more densely spaced in the centerareas of the long sides 1177′ of the anvil cap 1170′.

FIGS. 31 and 32 illustrate another anvil arrangement 1130″ that has ananvil cap 1170″ attached thereto. The anvil cap 1170″ is roughlyrectangular in shape and has an outer cap perimeter 1172″; however, theanvil cap 1170″ can comprise of any suitable configuration. The outercap perimeter 1172″ is configured to be inserted into acorrespondingly-shaped opening 1137″ in upper body portion 1165 of theanvil body 1132″ and received on axially extending internal ledgeportions 1139″ and 1190″ formed therein. See FIG. 32. The ledge portions1139″ and 1190″ are configured to support the corresponding long sides1177″ of the anvil cap 1170″. In an alternative embodiment, the anvilcap 1170″ is slid onto the internal ledges 1139″ and 1190″ through anopening in the distal end 1133″ of the anvil body 1132′. The anvil body1132″ and the anvil cap 1170″ may be fabricated from metal material thatis conducive to welding. A first weld 1178″ may extend around the entireperimeter 1172″ of the anvil cap 1170″ or it may only be located alongthe long sides 1177″ of the anvil cap 1170″ and not the distal end 1173″and/or proximal end thereof. The weld 1178″ may be continuous or it maybe discontinuous or intermittent. It will be appreciated that thecontinuous weld embodiment has more weld surface area due to theirregularly shape perimeter of the anvil cap 1170″ as compared to theembodiments with a straight perimeter sides such as the anvil caps shownin FIG. 26, for example. In those embodiments where the weld 1178″ isdiscontinuous or intermittent, the weld segments may be equallydistributed along the long sides 1177″ of the anvil cap 1170″ or theweld segments may be more densely spaced closer to the distal ends ofthe long sides 1177″ or more densely spaced closer to the proximal endsof the long sides 1177″. In still other arrangements, the weld segmentsmay be more densely spaced in the center areas of the long sides 1177″of the anvil cap 1170″.

Still referring to FIGS. 31 and 32, the anvil cap 1170″ may beadditionally welded to the anvil body 1132″ by a plurality of seconddiscrete “deep” welds 1192″. For example, each weld 1192″ may be placedat the bottom of a corresponding hole or opening 1194″ provided throughthe anvil cap 1170″ so that a discrete weld 1192″ may be formed alongthe portion of the anvil body 1132″ between the ledges 1190″ and 1139″.See FIG. 32. The welds 1192″ may be equally distributed along the longsides 1177″ of the anvil cap 1170″ or the welds 1192″ may be moredensely spaced closer to the distal ends of the long sides 1177″ or moredensely spaced closer to the proximal ends of the long sides 1177″. Instill other arrangements, the welds 1192″ may be more densely spaced inthe center areas of the long sides 1177″ of the anvil cap 1170″.

FIG. 33 illustrates another anvil cap 1170′″ that is configured to bemechanically interlocked to the anvil body 1132′″ as well as welded tothe upper body portion 1165. In this embodiment, a tongue-and-groovearrangement is employed along each long side 1177′″ of the anvil cap1170′″. In particular, a laterally extending continuous or intermittenttab 1195′″ protrudes from each of the long sides 1177′″ of the anvil cap1170′″. Each tab 1195″ corresponds to an axial slot 1197′″ formed in theanvil body 1132′″. The anvil cap 1170′″ is slid in from an opening inthe distal end of the anvil body 1132′″ to “mechanically” affix theanvil cap to the anvil body 1132′″. The tabs 1195′″ and slots 1197′″ maybe sized relative to each other to establish a sliding frictional fittherebetween. In addition, the anvil cap 1170′″ may be welded to theanvil body 1132′″. The anvil body 1132′″ and the anvil cap 1170′″ may befabricated from metal that is conducive to welding. The weld 1178′″ mayextend around the entire perimeter 1172′″ of the anvil cap 1170′″ or itmay only be located along the long sides 1177′″ of the anvil cap 1170′″.The weld 1178′″ may be continuous or it may be discontinuous orintermittent. In those embodiments where the weld 1178′″ isdiscontinuous or intermittent, the weld segments may be equallydistributed along the long sides 1177′″ of the anvil cap 1170′″ or theweld segments may be more densely spaced closer to the distal ends ofthe long sides 1177′″ or more densely spaced closer to the proximal endsof the long sides 1177′″. In still other arrangements, the weld segmentsmay be more densely spaced in the center areas of the long sides 1177′″of the anvil cap 1170′″.

The anvil embodiments described herein with anvil caps may provideseveral advantages. One advantage for example, may make the anvil andfiring member assembly process easier. That is, the firing member may beinstalled through the opening in the anvil body while the anvil isattached to the elongate channel. Another advantage is that the uppercap may improve the anvil's stiffness and resistance to theabove-mentioned flexure forces that may be experienced when clampingtissue. By resisting such flexure, the frictional forces normallyencountered by the firing member 1660 may be reduced. Thus, the amountof firing force required to drive the firing member from its starting toending position in the surgical staple cartridge may also be reduced.

FIG. 34 provides a side-by-side comparison of two anvils. A portion of afirst anvil 2030 of an end effector 2000 is depicted in the right halfof FIG. 34 and a portion of a second anvil 2030′ of an end effector2000′ is depicted in the left half of FIG. 34. The anvil 2030 comprisesa first longitudinal row of forming pockets 2032 a, a secondlongitudinal row of forming pockets 2032 b, and a third longitudinal rowof forming pockets 2032 c. The anvil 2030 further comprises alongitudinal slot 2033 which is configured to receive a firing member,such as firing member 2040, for example, as the firing member isadvanced through a staple firing stroke. The first longitudinal row offorming pockets 2032 a is positioned intermediate the longitudinal slot2033 and the second longitudinal row of forming pockets 2032 b, and thesecond longitudinal row of forming pockets 2032 b is positionedintermediate the first longitudinal row of forming pockets 2032 a andthe third longitudinal row of forming pockets 2032 c. As a result, thefirst longitudinal row of forming pockets 2032 a comprises an inner row,the third longitudinal row of forming pockets 2032 c comprises an outerrow, and the second longitudinal row of forming pockets 2032 b comprisesa middle or intermediate row.

Similar to the above, the anvil 2030′ comprises a first longitudinal rowof forming pockets 2032 a, a second longitudinal row of forming pockets2032 b, and a third longitudinal row of forming pockets 2032 c. Theanvil 2030′ further comprises a longitudinal slot 2033′ which isconfigured to receive a firing member, such as firing member 2040′, forexample, as the firing member is advanced through a staple firingstroke. The first longitudinal row of forming pockets 2032 a ispositioned intermediate the longitudinal slot 2033′ and the secondlongitudinal row of forming pockets 2032 b, and the second longitudinalrow of forming pockets 2032 b is positioned intermediate the firstlongitudinal row of forming pockets 2032 a and the third longitudinalrow of forming pockets 2032 c. As a result, the first longitudinal rowof forming pockets 2032 a comprises an inner row, the third longitudinalrow of forming pockets 2032 c comprises an outer row, and the secondlongitudinal row of forming pockets 2032 b comprises a middle orintermediate row.

The anvil 2030 comprises a flat, or an at least substantially flat,tissue engaging surface 2031. The forming pockets 2032 a, 2032 b, and2032 c are defined in the flat surface 2031. The flat surface 2031 doesnot have steps defined therein; however, embodiments are envisioned inwhich the anvil 2030 can comprise a stepped tissue engaging surface. Forinstance, the anvil 2030′ comprises a stepped tissue engaging surface2031′. In this embodiment, the forming pockets 2032 a and 2032 b aredefined in a lower step and the forming pockets 2032 c are defined in anupper step.

The firing member 2040′ comprises a coupling member 2042′ including acutting portion 2041. The cutting portion 2041 is configured andarranged to incise tissue captured between the anvil 2030′ and a staplecartridge 2010 (FIG. 35), for example. The firing member 2040′ isconfigured to push a sled having inclined surfaces distally during astaple firing stroke. The inclined surfaces are configured to liftstaple drivers within the staple cartridge 2010 to form staples 2020against the anvil 2030′ and eject the staples 2020 from the staplecartridge 2010. The coupling member 2042′ comprises projections, orcams, 2043′ extending laterally therefrom which are configured to engagethe anvil 2030′ during the staple firing stroke. Referring to FIG. 37,the projections 2043′ are comprised of longitudinally elongate shouldersextending from the coupling member 2042′. In other embodiments, theprojections 2043′ comprise a cylindrical pin which extends through thecoupling member 2042′. In any event, the projections 2043′ have flatlateral sides, or ends, 2047′.

The longitudinal slot 2033′ comprises lateral portions 2033 l′ extendinglaterally from a central portion 2033 c′ which are configured to receivethe projections 2043′. As illustrated in FIG. 34, the lateral portions2033 l′ of the longitudinal slot 2033′ have a rectangular, or at leastsubstantially rectangular, configuration having sharp corners. Eachlateral portion 2033 l′ of the slot 2033′ comprises a longitudinal camsurface 2035′ configured to be engaged by the projections 2043′ duringthe staple firing stroke. Each longitudinal cam surface 2035′ is definedon the upper side of a ledge 2037′ which extends longitudinally alongthe slot 2033′. Each longitudinal ledge 2037′ comprises a beam includinga fixed end attached to the main body portion of the anvil 2030′ and afree end configured to move relative to the fixed end. As such, eachlongitudinal ledge 2037′ can comprise a cantilever beam.

The coupling member 2042′ further comprises a foot, or cam, 2044 (FIG.35) configured to engage the staple cartridge 2010, or a jaw supportingthe staple cartridge 2010, during the staple firing stroke. Moreover,the projections 2043′ and the foot 2044 co-operate to position the anvil2030′ and the staple cartridge 2010 relative to one another. When theanvil 2030′ is movable relative to the staple cartridge 2010, thecoupling member 2042′ can cam the anvil 2030′ into position relative tothe staple cartridge 2010. When the staple cartridge 2010, or the jawsupporting the staple cartridge 2010, is movable relative to the anvil2030′, the coupling member 2042′ can cam the staple cartridge 2010 intoposition relative to the anvil 2030′.

Further to the above, the firing member 2040 comprises a coupling member2042 including a cutting portion 2041. The cutting portion 2041 isconfigured and arranged to incise tissue captured between the anvil 2030and a staple cartridge 2010 (FIG. 35). The firing member 2040 isconfigured to push a sled having inclined surfaces distally during astaple firing stroke. The inclined surfaces are configured to liftstaple drivers within the staple cartridge 2010 to form staples 2020against the anvil 2030 and eject the staples 2020 from the staplecartridge 2010. The coupling member 2042 comprises projections, or cams,2043 extending laterally therefrom which are configured to engage theanvil 2030 during the staple firing stroke. The projections 2043 havecurved, or rounded, lateral sides, or ends, 2047. The lateral ends 2047of the projections 2043 are entirely curved or fully-rounded. Eachlateral end 2047 comprises an arcuate profile extending between a topsurface of a projection 2043 and a bottom surface of the projection2043. In other embodiments, the lateral ends 2047 of the projections2043 are only partially curved.

The longitudinal slot 2033 comprises lateral portions 2033 l extendinglaterally from a central portion 2033 c which are configured to receivethe projections 2043. Each lateral portion 2033 l of the slot 2033comprises a longitudinal cam surface 2035 configured to be engaged bythe projections 2043 during the staple firing stroke. Each longitudinalcam surface 2035 is defined on the upper side of a ledge 2037 whichextends longitudinally along the slot 2033. Each longitudinal ledge 2037comprises a beam including a fixed end attached to the main body portionof the anvil 2030 and a free end configured to move relative to thefixed end. As such, each longitudinal ledge 2037 can comprise acantilever beam. As illustrated in FIG. 34, the lateral portions of thelongitudinal slot 2033 comprise a curved, or rounded, profile whichmatch, or at least substantially match, the curved ends 2047 of theprojections 2043.

The coupling member 2042 further comprises a foot, or cam, 2044 (FIG.35) configured to engage the staple cartridge 2010, or a jaw supportingthe staple cartridge 2010, during the staple firing stroke. Moreover,the projections 2043 and the foot 2044 co-operate to position the anvil2030 and the staple cartridge 2010 relative to one another. When theanvil 2030 is movable relative to the staple cartridge 2010, thecoupling member 2042 can cam the anvil 2030 into position relative tothe staple cartridge 2010. When the staple cartridge 2010, or the jawsupporting the staple cartridge 2010, is movable relative to the anvil2030, the coupling member 2042 can cam the staple cartridge 2010 intoposition relative to the anvil 2030.

Referring again to FIG. 34, the lateral portions 2033 l′ of thelongitudinal slot 2033′ extend a distance 2034′ from a centerline CL ofthe anvil 2030′. The lateral portions 2033 l′ extend over, or behind,the forming pockets 2032 a in the anvil 2030′. As illustrated in FIG.34, the lateral ends of the lateral portions 2033 l′ are aligned withthe outer edges of the forming pockets 2032 a. Other embodiments areenvisioned in which the lateral portions 2033 l′ extend laterally beyondthe forming pockets 2032 a, for example. That said, referring to FIG.36, the ledges 2037′ of the anvil 2030′ are long and, in certaininstances, the ledges 2037′ can deflect significantly under load. Insome instances, the ledges 2037′ can deflect downwardly such that alarge portion of the drive surfaces 2045′ defined on the bottom of theprojections 2043′ are not in contact with the cam surfaces 2035′. Insuch instances, the contact between the projections 2043′ and the camsurfaces 2035′ can be reduced to a point, such as point 2047′, forexample. In some instances, the contact between the projections 2043′and the cam surfaces 2035′ can be reduced to a longitudinally extendingline, which may appear to be a point when viewed from the distal end ofthe end effector, as illustrated in FIG. 36.

Moreover, referring again to FIG. 34, the projections 2043′ extend over,or behind, the forming pockets 2032 a in the anvil 2030′. The lateralends of the projections 2043′ extend over a longitudinal centerline 2062a of the forming pockets 2032 a. Other embodiments are envisioned inwhich the lateral ends of the projections 2043′ are aligned with thelongitudinal centerline 2062 a of the forming pockets 2032 a. Certainembodiments are envisioned in which the lateral ends of the projections2043′ do not extend to the longitudinal centerline 2062 a of the formingpockets 2032 a. In any event, referring again to FIG. 36, theprojections 2043′ can deflect upwardly, especially when the projections2043′ are long, such that a large portion of the drive surfaces 2045′ ofthe projections 2043′ are not in contact with the cam surfaces 2035′.This condition can further exacerbate the condition discussed above inconnection with the ledges 2037′. That being said, the projections 2043′may be able to better control the staple formation process occurring inthe forming pockets 2032 a, and/or the forming pockets 2032 b and 2032c, when the projections 2043′ extend to the outer edge of the formingpockets 2032 a or beyond, for instance.

Further to the above, the ledges 2037′ and the projections 2043′ candeflect in a manner which causes the load flowing between the firingmember 2040′ and the anvil 2030′ to be applied at the inner ends ofledges 2037′. As illustrated in FIG. 36, the contact points 2048′ are ator near the inner ends of the ledges 2037′. The deflection of the ledges2037′, and the projections 2043′, is the same or similar to that ofcantilever beams. As the reader should appreciate, the deflection of acantilever beam is proportional to the cube of the beam length when theload is applied at the end of the cantilever beam. In any event, gapsbetween the ledges 2037′ and the projections 2043′ can be created whenthe ledges 2037′ and/or the projections 2043′ deflect. Such gaps betweenportions of the ledges 2037′ and the projections 2043′ means that theforces flowing therebetween will flow through very small areas whichwill, as a result, increase the stress and strain experienced by theledges 2037′ and projections 2043′. This interaction is represented bystress risers, or concentrations, 2039′ and 2049′ in FIGS. 38 and 39where stress risers 2039′ are present in the ledges 2037′ and stressrisers 2049′ are present at the interconnection between the projections2043′ and the coupling member 2042′. Other stress risers, orconcentrations, may be present but, as discussed below, it is desirableto reduce or eliminate such stress risers.

Referring again to FIGS. 34 and 35, the lateral portions 2033 l of thelongitudinal slot 2033 each extend a distance 2034 from a centerline CLof the anvil 2030. The distance 2034 is shorter than the distance 2034′.Nonetheless, the lateral portions 2033 l extend over, or behind, theforming pockets 2032 a in the anvil 2030. As illustrated in FIG. 34, thelateral ends of the lateral portions 2033 l are not aligned with theouter edges of the forming pockets 2032 a. Moreover, the lateral ends ofthe lateral portions 2033 l do not extend beyond the outer edges of theforming pockets 2032 a; however, the lateral portions 2033 l extend overthe longitudinal centerlines 2062 a of the forming pockets 2032 a.Further to the above, the ledges 2037 are shorter than the ledges 2037′.As such, the ledges 2037 will experience less deflection, stress, andstrain than the ledges 2037′ for a given force applied thereto.

Other embodiments are envisioned in which the lateral portions 2033 l ofthe slot 2033 do not extend to the longitudinal centerline 2062 a of theforming pockets 2032 a. In certain embodiments, the lateral portions2033 l do not extend laterally over or overlap the forming pockets 2032a. Such shorter lateral portions 2033 l, further to the above, canreduce the deflection, stress, and strain in the ledges 2037. Owing tothe reduced deflection of the ledges 2037, the drive surfaces 2045defined on the bottom of the projections 2043 can remain in contact withthe cam surfaces 2035 of the ledges 2037. In such instances, the contactarea between the projections 2043 and the cam surfaces 2035 can beincreased as compared to the contact area between the projections 2043′and the cam surfaces 2035′.

Further to the above, the cross-sectional thickness of the ledges 2037isn't constant, unlike the ledges 2037′ which have a constantcross-sectional thickness. The ledges 2037 have a taperedcross-sectional thickness where the base of each ledge 2037 is widerthan its inner end owing to the rounded lateral ends of the lateral slotportions 2033 l. Such a configuration can serve to stiffen or strengthenthe ledges 2037 and reduce the deflection, stress, and strain of theledges 2037 as compared to the ledges 2037′. In at least one instance, aportion of a ledge 2037 is tapered while another portion of the ledge2037 has a constant cross-sectional thickness. In at least one otherinstance, the entirety of a ledge 2037 can be tapered such that none ofthe cross-sectional thickness is constant.

Moreover, referring again to FIGS. 34 and 35, the projections 2043extend over, or behind, the forming pockets 2032 a in the anvil 2030.The lateral ends of the projections 2043 do not extend over thelongitudinal centerline 2062 a of the forming pockets 2032 a. Otherembodiments are envisioned in which the lateral ends of the projections2043 are aligned with the longitudinal centerline 2062 a of the formingpockets 2032 a. Certain embodiments are envisioned in which the lateralends of the projections 2043 do not extend over the forming pockets 2032a at all. In any event, the upward deflection of the projections 2043may be less than the projections 2043′ and, as a result, a largercontact area can be present between the drive surfaces 2045 and the camsurfaces 2035.

Further to the above, the ledges 2037 and the projections 2043 candeflect in a manner which causes the load flowing between the firingmember 2040 and the anvil 2030 to be applied laterally along the lengthsof the ledges 2037 instead of at a single point and/or at end of theledges 2037. As a result, the forces flowing therebetween will flowthrough larger areas which will, as a result, reduce the stress andstrain experienced by the ledges 2037 and projections 2043 which canreduce or eliminate the stress risers discussed above in connection withthe ledges 2037′ and the projections 2043′, for example.

Referring again to FIG. 35, the foot 2044 of the coupling member 2042 iswider than the projections 2033. Stated another way, the lateral widthof the foot 2044 is wider than the width between the lateral ends of theprojections 2033. In such instances, the foot 2044 can deflect or strainmore than the projections and, as a result, the deflection of theprojections 2033 can be reduced. Alternative embodiments are envisionedin which the lateral width of the foot 2044 is the same as or less thanthe width between the lateral ends of the projections 2033; however,such embodiments can be otherwise configured to provide the desireddeflection and/or strain within the projections 2033.

As discussed above, an end effector can comprise an anvil, for example,which is movable between an open position and a closed position. In someinstances, the anvil is moved toward its closed position by a firingmember, such as firing member 2040 or 2040′, for example, when thefiring member is moved distally. In other instances, the anvil is movedtoward its closed position prior to the firing member being advanceddistally to perform a staple firing stroke. In either event, the anvilmay not move into its entirely closed position until the firing memberapproaches or reaches the end of its staple firing stroke. As a result,the anvil is progressively closed by the firing member. In at least onesuch instance, the anvil may progressively close owing to thick tissuecaptured between the anvil and the staple cartridge. In some instances,the anvil may actually deflect or deform during the staple firing strokeof the firing member. Such circumstances are generally controlled,however, by the upper projections and the bottom foot of the firingmember.

Turning now to FIG. 37, the drive surfaces 2045′ defined on theprojections 2043′ are flat, or at least substantially flat. Moreover,the drive surfaces 2045′ are configured to flushingly engage the flat,or at least substantially flat, cam surfaces 2035′ defined on the anvil2030′ when the anvil 2030′ is in a completely closed position. Statedanother way, the drive surfaces 2045′ engage the cam surfaces 2035′ in aface-to-face relationship when the anvil 2030′ is in a completely flatorientation. A flat orientation of the anvil 2030′ is depicted inphantom in FIG. 37. In such instances, the drive surfaces 2045′ areparallel, or at least substantially parallel, to the longitudinal pathof the firing member 2040′ during the staple firing stroke. As discussedabove, however, the anvil 2030′ may progressively close during thefiring stroke and, as a result, the anvil 2030′ may not always be in anentirely closed position. As a result, the drive surfaces 2045′ may notalways be aligned with the cam surfaces 2035′ and, in such instances,the projections 2043′ may gouge into the ledges 2037′ of the anvil 2030.FIG. 37 depicts such instances with solid lines.

Further to the above, the drive surfaces 2045′ of the projections 2043′and/or the cam surfaces 2035′ defined on the ledges 2037′ canplastically deform if the firing member 2040′ has to progressively closethe anvil 2030′ into its entirely closed position. In certain instances,the cam surfaces 2035′ can gall, for example, which can increase theforce needed to complete the staple firing stroke. More specifically,plastic strain of the projections 2043′ and/or the anvil ledges 2037′can cause energy losses as the metal is deformed beyond the plasticlimits. At that point, galling occurs and the frictional co-efficient ofthe coupling increases substantially. The energy losses can be in theorder of about 10%-30%, for example, which can increase the force neededto fire the firing member in the order of about 10%-30%. Moreover, theforce needed to complete subsequent staple firing strokes with the endeffector 2000′ may increase in such instances in the event that the endeffector 2000′ is reused.

Turning now to FIGS. 40-42, a firing member 2140 comprises a firing barand a coupling member 2142 attached to the firing bar. The couplingmember 2142 comprises a connector 2148 which connects the couplingmember 2142 to the firing bar. The coupling member 2142 furthercomprises a cutting member 2041 configured to incise the tissue of apatient during a staple firing stroke. The coupling member 2142 alsocomprises projections 2143 configured to engage an anvil, such as anvil2030 or 2030′, for example, and, in addition, a foot 2144 configured toengage a staple cartridge jaw during the staple firing stroke. Eachprojection 2143 comprises a drive surface 2145 defined on the bottomside thereof. Each projection 2143 further comprises aproximally-extending cam transition 2147 and a radiused-transition 2149extending around the perimeter of the projection 2143. The couplingmember 2142 further comprises intermediate projections 2146 extendinglaterally therefrom which are configured to prevent the firing member2140 from performing the staple firing stroke when an unspent staplecartridge is not positioned in front of the firing member 2140 at theoutset of the staple firing stroke.

Further to the above, the drive surfaces 2145 of the projections 2143are not parallel to the longitudinal path 2160 of the firing member2140. Rather, the drive surfaces 2145 extend transversely to thelongitudinal path 2160. In at least one instance, the distal end of eachdrive surface 2145 is positioned further away from the longitudinal path2160 than the proximal end. Such an arrangement can reduce or eliminatethe problems described above in connection with the progressive closureof the anvil 2130. More specifically, in at least one instance, if theanvil 2130 will move through a range of motion between about 4 degreesand about 0 degrees with respect to the longitudinal path 2160 duringthe progressive closure, then the drive surface 2145 could be orientedat about 2 degrees with respect to the longitudinal path 2160, forexample, which represents the midpoint in the range of progressiveclosure. Other embodiments are possible. For instance, if the anvil 2130will move through a range of motion between about 1 degree and about 0degrees with respect to the longitudinal path 2160 during theprogressive closure, then the drive surfaces 2145 could be oriented atabout 1 degree with respect to the longitudinal path 2160, for example,which represents the upper bound in the range of progressive closure. Invarious instances, the firing member 2140 may be required toprogressively close the anvil 2130 through a 5 degree range of motion,for example. In other instances, the firing member 2140 may be requiredto progressively the anvil 2130 through a 10 degree range of motion, forexample. In some instances, the anvil 2130 may not reach its completelyclosed position and, as a result, the progressive closure of the anvil2130 may not reach 0 degrees.

Further to the above, the drive surface 2145 of the projection 2143 isnot parallel to the drive surface of the foot 2144. Referring primarilyto FIG. 41, the drive surface 2145 extends along an axis 2183 and thedrive surface of the foot 2144 extends along an axis 2184. In at leastone instance, the drive surface 2145 is oriented at an about 0.5 degreeangle with respect to the drive surface of the foot 2144, for example.Other instances are envisioned in which the drive surface 2145 isoriented at an about 1 degree angle with respect to the drive surface ofthe foot 2144, for example. Certain instances are envisioned in whichthe drive surface 2145 is oriented between about 0.5 degrees and about 5degrees with respect to the drive surface of the foot 2144, for example.The drive surface of the foot 2144 is parallel to the longitudinal path2160; however, other embodiments are envisioned in which the drivesurface of the foot 2144 is not parallel to the longitudinal path 2160.

The examples provided above were discussed in connection with a movableanvil; however, it should be understood that the teachings of suchexamples could be adapted to any suitable movable jaw, such as a movablestaple cartridge jaw, for example. Similarly, the examples providedelsewhere in this application could be adapted to any movable jaw.

Turning now to FIGS. 43-45, a firing member 2240 comprises a firing barand a coupling member 2242 attached to the firing bar. The couplingmember 2242 comprises a connector 2148 which connects the couplingmember 2242 to the firing bar. The coupling member 2242 furthercomprises a cutting member 2041 configured to incise the tissue of apatient during a staple firing stroke. The coupling member 2242 alsocomprises projections 2243 configured to engage an anvil, such as anvil2030 or 2030′, for example, and, in addition, a foot 2144 configured toengage a staple cartridge jaw during the staple firing stroke. Eachprojection 2243 comprises a drive surface 2245 defined on the bottomside thereof. Each projection 2243 further comprises aradiused-transition 2249 extending around the perimeter thereof. Thecoupling member 2242 further comprises intermediate projections 2146extending laterally therefrom which are configured to prevent the firingmember 2240 from performing the staple firing stroke when an unspentstaple cartridge is not positioned in front of the firing member 2240 atthe outset of the staple firing stroke.

Further to the above, each projection 2243 comprises a leading, orproximal, end 2251 configured to engage the anvil and, in addition, atrailing end. The leading end of each projection 2243 is different thanthe lagging, or trailing, end of the projection 2243. The leading end2251 comprises a radius which extends from the bottom drive surface 2245of the projection 2243 to a location positioned above a longitudinalcenterline 2250 of the projection 2243. The leading end 2251 comprises asingle radius of curvature; however, the leading end 2251 can becomprised of more than one radius of curvature. Each projection 2243further comprises a radiused edge 2259 between the radiused leading end2251 and the top surface of the projection 2243. The radius of curvatureof the edge 2259 is smaller than the radius of curvature of the leadingend 2251. Other embodiments are envisioned in which the entirety of, orat least a portion of, the leading end 2251 is linear. In any event, theconfiguration of the leading end 2251 can shift the force, or load,transmitted between the firing member 2240 and the anvil away from theleading end 2251 toward the trailing end of the projection 2243. Statedanother way, the configuration of the leading end 2251 may prevent theleading end 2251 from becoming the focal point of the transmitted forcebetween the firing member 2240 and the anvil. Such an arrangement canprevent or reduce the possibility of the firing member 2240 becomingstuck against the anvil and can reduce the force required to move thefiring member 2240 distally.

Turning now to FIGS. 46-48, a firing member 2340 comprises a firing barand a coupling member 2342 attached to the firing bar. The couplingmember 2342 comprises a connector 2148 which connects the couplingmember 2342 to the firing bar. The coupling member 2342 furthercomprises a cutting member 2041 configured to incise the tissue of apatient during a staple firing stroke. The coupling member 2342 alsocomprises projections 2343 configured to engage an anvil, such as anvil2030 or 2030′, for example, and, in addition, a foot 2144 configured toengage a staple cartridge jaw during the staple firing stroke. Eachprojection 2343 comprises a drive surface defined on the bottom sidethereof. Each projection 2343 further comprises a radiused-transition2349 extending around the perimeter thereof. The coupling member 2342further comprises intermediate projections 2146 extending laterallytherefrom which are configured to prevent the firing member 2340 fromperforming the staple firing stroke when an unspent staple cartridge isnot positioned in front of the firing member 2340 at the outset of thestaple firing stroke.

Further to the above, each projection 2343 comprises a radiused leadingend 2351. The leading end 2351 is similar to the leading end 2251 andcomprises a curved surface which extends across the centerline 2350 ofthe projection 2343. The leading end 2251 has a different configurationthan the trailing end of the projection 2243. Each projection 2343further comprises a lateral side, or end, 2352. Each lateral end 2352comprises a flat surface which is positioned intermediate radiused, orcurved, edges 2347. A first radiused edge 2347 is positionedintermediate a top surface of the projection 2343 and the lateral end2352 and, in addition, a second radiused edge 2347 is positionedintermediate a bottom surface of the projection 2343 and the lateral end2352.

Turning now to FIGS. 49-51, a firing member 2440 comprises a firing barand a coupling member 2442 attached to the firing bar. The couplingmember 2442 comprises a connector 2148 which connects the couplingmember 2442 to the firing bar. The coupling member 2442 furthercomprises a cutting member 2041 configured to incise the tissue of apatient during a staple firing stroke. The coupling member 2442 alsocomprises projections 2443 configured to engage an anvil, such as anvil2030 or 2030′, for example, and, in addition, a foot 2144 configured toengage a staple cartridge jaw during the staple firing stroke. Eachprojection 2443 comprises a drive surface 2445 defined on the bottomside thereof. Each projection 2443 further comprises aradiused-transition extending around the perimeter thereof. The couplingmember 2442 further comprises intermediate projections 2146 extendinglaterally therefrom which are configured to prevent the firing member2440 from performing the staple firing stroke when an unspent staplecartridge is not positioned in front of the firing member 2440 at theoutset of the staple firing stroke.

Further to the above, the lateral sides, or ends, of each projection2443 are defined by more than one radius of curvature. Each projection2443 comprises a first radius of curvature 2447 a extending from thebottom drive surface 2445 and a second radius of curvature 2447 bextending from the top surface of the projection 2443. The first radiusof curvature 2447 a is different than the second radius of curvature2447 b. For instance, the first radius of curvature 2447 a is largerthan the second radius of curvature 2447 b; however, the curvatures 2447a and 2447 b can comprise any suitable configuration. Referringprimarily to FIG. 51, the first radius of curvature 2447 a extendsupwardly past a centerline 2450 of the projection 2443.

Turning now to FIGS. 52-54, a firing member 2540 comprises a firing barand a coupling member 2542 attached to the firing bar. The couplingmember 2542 comprises a connector 2148 which connects the couplingmember 2542 to the firing bar. The coupling member 2542 furthercomprises a cutting member 2041 configured to incise the tissue of apatient during a staple firing stroke. The coupling member 2542 alsocomprises projections 2543 configured to engage an anvil, such as anvil2030 or 2030′, for example, and, in addition, a foot 2144 configured toengage a staple cartridge jaw during the staple firing stroke. Eachprojection 2543 comprises a drive surface defined on the bottom sidethereof. Each projection 2543 further comprises a radiused-transitionextending around the perimeter thereof. The coupling member 2542 furthercomprises intermediate projections 2146 extending laterally therefromwhich are configured to prevent the firing member 2540 from performingthe staple firing stroke when an unspent staple cartridge is notpositioned in front of the firing member 2540 at the outset of thestaple firing stroke.

Further to the above, each projection 2543 comprises a lateral side, orend, 2552 which is flat, or at least substantially flat. Each projection2543 further comprises a radiused transition 2547 extending around thelateral end 2552. Each projection 2543 is symmetrical, or at leastsubstantially symmetrical, about a longitudinal centerline which extendsthrough the lateral end 2552. Moreover, the top surface and the bottomsurface of each projection 2543 are parallel to one another.

Referring primarily to FIG. 53, the leading end 2551 of each projection2543 is positioned distally with respect to a cutting edge 2042 of thecutting portion 2041. The trailing end 2559 of each projection 2543 ispositioned proximally with respect to the cutting edge 2042. As aresult, the projections 2043 longitudinally span the cutting edge 2042.In such instances, the firing member 2540 can hold the anvil and thestaple cartridge together directly at the location in which the tissueis being cut.

Turning now to FIGS. 55-57, a firing member 2640 comprises a firing barand a coupling member 2642 attached to the firing bar. The couplingmember 2642 comprises a connector 2148 which connects the couplingmember 2642 to the firing bar. The coupling member 2642 furthercomprises a cutting member 2041 configured to incise the tissue of apatient during a staple firing stroke. The coupling member 2642 alsocomprises projections 2643 configured to engage an anvil, such as anvil2030 or 2030′, for example, and, in addition, a foot 2144 configured toengage a staple cartridge jaw during the staple firing stroke. Eachprojection 2643 comprises a drive surface 2645 defined on the bottomside thereof. Each projection 2643 further comprises aradiused-transition 2649 extending around the perimeter thereof. Thecoupling member 2642 further comprises intermediate projections 2146extending laterally therefrom which are configured to prevent the firingmember 2640 from performing the staple firing stroke when an unspentstaple cartridge is not positioned in front of the firing member 2640 atthe outset of the staple firing stroke.

Further to the above, each projection 2643 further comprises a lateralend 2652, a bottom drive surface 2645, and a top surface 2647. Thebottom drive surface 2645 is flat and is parallel to the longitudinalfiring path 2660 of the firing member 2640. Referring primarily to FIG.57, the top surface 2647 is flat, but not parallel to the longitudinalfiring path 2660. Moreover, the top surface 2647 is not parallel to thebottom surface 2645. As a result, each projection 2643 is asymmetrical.In fact, the orientation of the top surface 2647 shifts the moment ofinertia of the projection 2643 above the lateral end 2652. Such anarrangement can increase the bending stiffness of the projections 2643which can reduce the deflection of the projections 2643.

Turning now to FIGS. 58-60, a firing member 2740 comprises a firing barand a coupling member 2742 attached to the firing bar. The couplingmember 2742 comprises a connector 2148 which connects the couplingmember 2742 to the firing bar. The coupling member 2742 furthercomprises a cutting member 2041 configured to incise the tissue of apatient during a staple firing stroke. The coupling member 2742 alsocomprises projections 2743 configured to engage an anvil, such as anvil2030 or 2030′, for example, and, in addition, a foot 2144 configured toengage a staple cartridge jaw during the staple firing stroke. Eachprojection 2743 comprises a drive surface defined on the bottom sidethereof. The coupling member 2742 further comprises intermediateprojections 2146 extending laterally therefrom which are configured toprevent the firing member 2740 from performing the staple firing strokewhen an unspent staple cartridge is not positioned in front of thefiring member 2740 at the outset of the staple firing stroke.

Further to the above, each projection 2743 comprises a first, orleading, portion 2753 a and a second, or lagging, portion 2753 bpositioned distally behind the leading portion 2753 a. The leadingportion 2753 a comprises a curved lead-in surface 2751 defined on thedistal end thereof which is configured to initially engage the anvil.The leading portion 2753 a further comprises a first, or leading, drivesurface 2745 a defined on the bottom side thereof. Similarly, thelagging portion 2753 b comprises a second, or lagging, drive surface2745 b defined on the bottom side thereof. Each projection 2743 furthercomprises a transition 2752 defined between the leading portion 2753 aand the lagging portion 2753 b.

As the firing member 2740 is advanced distally, further to the above,the drive surfaces 2745 a and 2745 b can co-operate to engage andposition the anvil. In certain embodiments, the drive surfaces 2745 aand 2745 b define a drive plane which is parallel, or at leastsubstantially parallel, to the longitudinal path 2760 of the firingmember 2740 during the staple firing stroke. In some instances, however,only the leading drive surface 2745 a may engage the cam surface definedon the anvil. Such instances can arise when the firing member 2740progressively closes the anvil, for example.

In other embodiments, referring to FIGS. 69 and 71, the leading drivesurface 2745 a is positioned above the lagging drive surface 2745 b.Stated another way, the leading drive surface 2745 a is positionedfurther away from the longitudinal path 2760 than the lagging drivesurface 2745 b such that both drive surfaces 2745 a and 2745 b remain incontact with the anvil during the staple firing stroke. In at least oneinstance, the drive surfaces 2745 a and 2745 b can define a drive planewhich is transverse to the longitudinal path 2760. In certain instances,a 1 degree angle, for example, can be defined between the drive planeand the longitudinal path 2760. In various instances, the leading drivesurface 2745 a is positioned vertically above the lagging drive surface2745 b by approximately 0.001″, for example. In other embodiments, theleading drive surface 2745 a is positioned vertically above the laggingdrive surface 2745 b by approximately 0.002″, for example. In certaininstances, the leading drive surface 2745 a is positioned above thelagging drive surface 2745 b a distance which is between about 0.001″and about 0.002″, for example

In certain instances, referring again to FIG. 70, only the lagging drivesurfaces 2745 b may be in contact with the cam surfaces of the anvilwhen the firing member 2740 progressively closes the anvil. In suchinstances, the leading drive surfaces 2745 a are not in contact with thecam surfaces of the anvil. Such an arrangement can reduce the plasticdeformation of the projections 2743 and reduce to force needed toadvance the firing member 2740 distally as compared to when only theleading drive surfaces 2745 a are in contact with the cam surfaces ofthe anvil. When the anvil begins to flex owing to the staple formingload being applied to the anvil, in some instances, the anvil can flexupwardly into contact with the leasing drive surfaces 2745 a asillustrated in FIG. 71.

The leading portion 2753 a is thicker than the lagging portion 2753 b.Stated another way, the leading portion 2753 a has a larger bendingmoment of inertia than the lagging portion 2753 b which can resist theupward bending of the projection 2743. As a result, the lagging portion2753 b can deflect upwardly more than the leading portion 2753 a. Insuch instances, it is more likely that both portions 2753 a and 2753 bof the projections 2743 can remain in contact with the anvil during thestaple firing stroke even though the firing member 2740 is being used toprogressively close the anvil. Moreover, the leading portion 2753 a alsohas a larger shear thickness than the lagging portion 2753 b which canbetter resist shear forces transmitted through the projections 2743. Theleading portion 2753 a is often exposed to greater shear forces than thelagging portion 2753 b and, as a result, can benefit from the increasedshear thickness. If it is believed that the lagging portion 2753 b mayexperience greater shear forces than the leading projection 2753 a, thenthe lagging portion 2753 b can have a greater shear thickness than theleading portion 2753 a, for example.

Turning now to FIGS. 61-63, a firing member 2840 comprises a firing barand a coupling member 2842 attached to the firing bar. The couplingmember 2842 comprises a connector 2148 which connects the couplingmember 2842 to the firing bar. The coupling member 2842 furthercomprises a cutting member 2041 configured to incise the tissue of apatient during a staple firing stroke. The coupling member 2842 alsocomprises projections configured to engage an anvil, such as anvil 2030or 2030′, for example, and, in addition, a foot 2144 configured toengage a staple cartridge jaw during the staple firing stroke. Asdescribed in greater detail below, each projection comprises a drivesurface defined on the bottom side thereof. The coupling member 2842further comprises intermediate projections 2146 extending laterallytherefrom which are configured to prevent the firing member 2840 fromperforming the staple firing stroke when an unspent staple cartridge isnot positioned in front of the firing member 2840 at the outset of thestaple firing stroke.

Further to the above, each side of the coupling member comprises afirst, or leading, projection 2843 d and a second, or lagging,projection 2843 p positioned behind the leading projection 2843 d. Theleading projection 2843 d comprises a curved lead-in surface 2851 ddefined on the distal end thereof which is configured to initiallyengage the anvil. The leading projection 2843 d further comprises afirst, or leading, drive surface 2845 d defined on the bottom sidethereof. Similarly, the lagging projection 2843 p comprises a curvedlead-in surface 2851 p defined on the distal end thereof which isconfigured to engage the anvil. The lagging projection 2843 p furthercomprises a second, or lagging, drive surface 2845 p defined on thebottom side thereof.

As the firing member 2840 is advanced distally, further to the above,the drive surfaces 2845 d and 2845 p can co-operate to engage andposition the anvil. In certain embodiments, the drive surfaces 2845 dand 2845 p define a drive plane which is parallel, or at leastsubstantially parallel, to the longitudinal path 2860 of the firingmember 2840 during the staple firing stroke. In other embodiments, theleading drive surface 2845 d is positioned above the lagging drivesurface 2845 p. Stated another way, the leading drive surface 2845 d ispositioned further away from the longitudinal path 2860 than the laggingdrive surface 2845 p. In at least one instance, the drive surfaces 2845d and 2845 p can define a drive plane which is transverse to thelongitudinal path 2860. In certain instances, a 1 degree angle, forexample, can be defined between the drive plane and the longitudinalpath 2860.

Further to the above, the leading projections 2843 d and the laggingprojections 2843 p can move relative to each other. In variousinstances, a leading projection 2843 d and a lagging projection 2843 pon one side of the coupling member 2842 can move independently of oneanother. Such an arrangement can allow the projections 2843 d and 2843 pto independently adapt to the orientation of the anvil, especially whenthe firing member 2840 is used to progressively close the anvil. As aresult, both of the projections 2843 d and 2843 p can remain engagedwith the anvil such that forces flow between the firing member 2840 andthe anvil at several locations and that the plastic deformation of theprojections is reduced.

FIG. 68 depicts the energy required for a first firing member tocomplete a firing stroke, labeled as 2090′, and a second firing memberto complete a firing stroke, labeled as 3090. The firing stroke 2090′represents a condition in which significant plastic deformation andgalling is occurring. The firing stroke 3090 represents an improvementover the firing stroke 2090′ in which the deformation of the firingmember and anvil ledge is mostly elastic. It is believed that, incertain instances, the plastic strain experienced by the firing memberand/or anvil can be reduced by about 40%-60%, for example, by employingthe teachings disclosed herein.

The various embodiments described herein can be utilized to balance theloads transmitted between a firing member and an anvil. Such embodimentscan also be utilized to balance the loads transmitted between a firingmember and a staple cartridge jaw. In either event, the firing membercan be designed to provide a desired result but it should be understoodthat such a desired result may not be achieved in some circumstancesowing to manufacturing tolerances of the stapling instrument and/or thevariability of the tissue thickness captured within the end effector,for example. In at least one instance, the upper projections and/or thebottom foot of the firing member, for example, can comprise wearablefeatures which are configured to allow the firing member to define abalanced interface with the anvil.

Further to the above, referring now to FIGS. 64-67, a firing member 2940comprises lateral projections 2943. Each projection 2943 compriseslongitudinal ridges 2945 extending from the bottom thereof. The ridges2945 are configured to plastically deform and/or smear when the firingmember 2940 is advanced distally to engage the anvil. The ridges 2945are configured to quickly wear in, or take a set, so as to increase thecontact area between the projections 2943 and the anvil and providebetter load balancing between the firing member 2940 and the anvil. Suchan arrangement can be especially useful when the end effector is used toperform several staple firing strokes. In addition to or in lieu of theabove, one or more wearable pads can be attached to the projections ofthe firing member which can be configured to plastically deform.

FIGS. 72 and 73 depict a surgical stapling anvil, or anvil jaw, 3100 foruse with a surgical stapling instrument. The anvil 3100 is configured todeform staples during a surgical stapling procedure. The anvil 3100comprises an anvil body 3101 and an anvil cap 3110. The anvil body 3101and the anvil cap 3110 are welded together. The anvil body 3101comprises a proximal portion 3102 comprising a coupling portion 3103.The coupling portion 3103 is configured to be assembled to an endeffector of a surgical stapling instrument to permit rotation of theanvil jaw 3000 relative to a corresponding jaw such as, for example, astaple cartridge jaw. Embodiments are envisioned where the anvil jaw isfixed relative to the staple cartridge jaw and, in such instances, thestaple cartridge jaw can rotate relative to the anvil jaw. The anvilbody 3101 further comprises a distal tip portion 3104, outer edges 3107,and a planar, tissue-facing surface 3106. The tissue-facing surface 3106comprises staple-forming pockets defined therein configured to deformstaples during a surgical stapling procedure. The anvil body 3101further comprises a longitudinal cavity, or aperture, 3105 configured toreceive the anvil cap 3110 therein. As discussed in greater detailbelow, the longitudinal cavity 3105 can comprise corresponding surfacesconfigured to mate with corresponding surfaces of the anvil cap 3110during assembly. Certain surfaces may be configured for welding whileothers may be configured only for alignment during assembly.

The anvil cap 3110 comprises a proximal end 3111, a distal end 3112, anda continuous perimeter, or edge, 3113. When the anvil body 3101 and theanvil cap 3110 are assembled and/or welded together, the edge 3113 maybe flush, or substantially flush, with the top surface 3108 of the anvilbody 3101 so as to provide a smooth upper surface of the surgicalstapling anvil 3100 although a step in the seam therebetween may bepossible. Further to the above, the anvil cap 3110 comprises a roundedupper surface 3114. The upper surface 3114 can be contoured and/orrounded, for example, in order to provide a continuous, curved uppersurface of the surgical stapling anvil 3100 when the anvil body 3101 andthe anvil cap 3110 are welded together. In various instances, thecontinuous edge 3113 is a feature configured for welding, as discussedbelow.

The two-piece surgical stapling anvil 3100 can permit the polishing ofinternal surfaces within the anvil 3100 during manufacturing.Manufacturing these parts can include processes resulting in a less thandesirable surface finish of various surfaces within the anvil. Improvingthe finish of various internal surfaces can reduce internal frictionalforces between the anvil and a staple firing member passingtherethrough. Reducing the internal frictional forces can reduce theforce required for the firing member to move through its staple-firingstroke. Reducing the force required for a firing member to move throughits staple-firing stroke can result in the reduction of the size ofcertain components resulting in the reduction of overall instrument sizewhich is desirable. Such an arrangement can also reduce the number ofinstances of instrument failure. That said, there are challenges to atwo-piece welded anvil. For example, a two-piece welded anvil maydeflect more than a unitary anvil in some instances. In other words, atwo-piece anvil may be less stiff than a unitary anvil and lessresistant to bending. In addition, lateral deflection, or rotation, ofthe sides of an anvil away from a firing member or longitudinalinstrument axis can cause staples to deform improperly. Such deflectioncan result in a vertical expansion of the overall system resultingformed staples with a formed height which is not the intended formedheight. Moreover, such deflection may permit a firing member tovertically tear through an anvil of which it is camming. Also,transverse deflection, or rotation, may require more firing force to beapplied to the firing member complete its firing stroke. For example,the distal portion of an anvil may deflect away from the staplecartridge due to the application of tissue-induced pressure. Minimizingthis deflection can be important to create properly formed staples. Theabove being said, the presence of both transverse and lateral deflectioncan have a compounding effect. In fact, transverse deflection can inducelateral deflection of the anvil.

FIG. 74 depicts a portion of a surgical stapling anvil 3200 comprisingan anvil body 3210 and an anvil cap 3220 welded to the anvil body 3210with a weld 3201. Although only a portion of the surgical stapling anvil3200 is illustrated, it should be understood that a mirrored portion ofthe illustrated portion exists to complete the surgical stapling anvil3200. The illustrated and mirrored portions will be discussedconcurrently going forward. The anvil body 3210 comprises atissue-facing surface 3211 comprising a plurality of staple-formingpockets 3212 defined therein, ledges 3215 comprising camming surfaces3216 configured the be contacted by the anvil-camming features of afiring member of a surgical stapling instrument, and a longitudinal slot3213 configured to receive the firing member therethrough. The anvilbody 3210 further comprises outer edges 3214. The ledges 3215 areconfigured to bear, or support, a distributed load force 3231 applied bya firing member as the firing member moves through a staple-firingstroke. The anvil body 3210 further comprises a ledge 3217 configured tohold the anvil cap 3220 during welding. The ledge 3217 can aid inassembly and can ensure the proper alignment of the anvil cap 3220 andthe anvil body 3210. The ledge 3217 can also act as a feature to improveoverall anvil stiffness. The anvil cap 3220 comprises an upper portion3223, a lower portion 3221, and a ledge 3224 configured to rest on theledge 3217 before, during, and after welding.

The upper portion 3223 of the anvil cap 3220 and the anvil body 3210 arewelded together with the weld 3201. Welding access is provided bybeveled edges on one or both of the anvil body 3210 and the anvil cap3220. In this instance, the weld surfaces of the anvil body 3210 and theanvil cap 3220 are vertical and, as a result, the weld 3201 is vertical.The weld 3201 comprises a weld length, or depth, labeled by 3202. Theweld depth 3202 is about 0.030 inches, for example. Notably, the weld3201 does not penetrate the anvil 3200 to the horizontal surfaces of theledges 3217, 3224. With this arrangement, the anvil body 3210 will tendto rotationally deflect about the pivot axis P owing to the combinationof forces applied to the anvil body 3210 by the firing member and thetissue. As the firing member cams the surfaces 3216 by pressing on theledges 3215, represented by distributed load force 3231, and the tissueand the cartridge push on the tissue-facing surface 3211, represented bydistributed load force 3232, both sides of the anvil body 3210 (only oneshown in FIG. 74) may tend to rotate about a pivot axis P and deflectvertically and/or outwardly with respect to the firing member and theanvil cap 3220. This deflection, represented by deflection 3233, ispermitted due to the lack of weld penetration from the provided weldarrangement. In some instances, the anvil body 3210 and the anvil cap3220 may spread apart at an non-welded portion, or seam, 3204 having alength 3203.

FIG. 75 depicts a portion of a surgical stapling anvil 3300 comprisingan anvil body 3310 and an anvil cap 3320 welded to the anvil body 3310with a weld 3301. Although only a portion of the surgical stapling anvil3300 is illustrated, it should be understood that a mirrored portion ofthe illustrated portion exists to complete the surgical stapling anvil3300. The illustrated and mirrored portions will be discussedconcurrently going forward. The anvil body 3310 comprises atissue-facing surface 3311 comprising a plurality of staple-formingpockets 3312 defined therein, ledges 3315 comprising camming surfaces3316 configured to be contacted by the anvil-camming features of afiring member of a surgical stapling instrument, and a longitudinal slot3313 configured to receive a firing member therethrough. The anvil body3310 further comprises outer edges 3314. The ledges 3315 are configuredto bear, or support, a distributed load force 3331 applied by the firingmember as the firing member moves through a staple-firing stroke. Theanvil body 3310 further comprises an upper portion 3317 extending fromthe slot 3313 to the outer edge 3314. The anvil cap 3320 comprises anupper portion 3323, a lower portion 3321, and a ledge 3224 configured torest on the upper portion 3317 before, during, and after welding.

The ledge 3324 of the anvil cap 3320 and the upper portion 3317 of theanvil body 3310 are welded together with the weld 3301. Welding accessis provided by a beveled edge of the anvil cap 3320. In this instance,the weld surfaces of the anvil body 3310 and the anvil cap 3320 arehorizontal and, as a result, the weld 3301 is horizontal. The weld 3301comprises a weld length, or depth, labeled by 3302. The weld depth 3302is about 0.030 inches, for example. Such a weld depth 3302, however,creates a non-welded portion 3304 having a non-welded width 3303. Thenon-welded width is about 0.080 inches, for example. With thisarrangement, the anvil body 3310 will tend to rotationally deflect aboutthe pivot axis P and the upper portion 3317 and the ledge 3324 will tendto compress during deflection. However, a non-welded width 3303 extendsbetween the slot 3313 and beyond the second row of staple-formingpockets 3312. In various instances, the combination of forces applied tothe anvil body 3310 by the firing member and the tissue can generate adeflection indicated by deflection 3333. As the firing member cams theanvil 3300 toward the opposing staple cartridge by pressing on theledges 3315, represented by distributed load force 3331, and as thetissue and the staple cartridge push on the tissue-facing surface 3311,represented by distributed load force 3332, both sides of the anvil body3310 (only one shown in FIG. 75) may tend to rotate and deflectvertically and/or outwardly with respect to the firing member. Thisdeflection 3333 occurs due to the lack of weld penetration, thesignificant non-welded width 3304, as well as the horizontal weldarrangement 3301.

FIG. 76 depicts a portion of a surgical stapling anvil 3400 comprisingan anvil body 3410 and an anvil cap 3420 welded to the anvil body 3410with a weld 3401. Although only a portion of the surgical stapling anvil3400 is illustrated, it should be understood that a mirrored portion ofthe illustrated portion exists to complete the surgical stapling anvil3400. The illustrated and mirrored portions will be discussedconcurrently going forward. The anvil body 3410 comprises atissue-facing surface 3411 comprising a plurality of staple-formingpockets 3412 defined therein, ledges 3415 comprising camming surfaces3416 configured to be contacted by the anvil-camming features of afiring member of a surgical stapling instrument, and a longitudinal slot3413 configured to receive the firing member therethrough. The anvilbody 3410 further comprises outer edges 3414. The ledges 3415 areconfigured to bear, or support, a distributed load force 3431 applied bythe firing member as the firing member moves through a staple-firingstroke. The anvil body 3410 further comprises a ledge 3417 configured tohold the anvil cap 3420 during welding. The ledge 3417 can aid inassembling the cap 3420 and the body 3410 and can ensure the properalignment of the anvil cap 3420 and the anvil body 3410. The ledge 3417can also improve the overall anvil stiffness of the anvil 3400. Theanvil cap 3420 comprises an upper portion 3423, a lower portion 3421,and a ledge 3424 configured to rest on the ledge 3417 before, during,and after welding.

The upper portion 3423 of the anvil cap 3420 and the anvil body 3410 arewelded together with the weld 3401. Welding access is provided bybeveled edges of on or both of the anvil body 3410 and the anvil cap3420. In this instance, the weld surfaces of the anvil body 3410 and theanvil cap 3420 are angled and, as a result, the weld 3401 is angled. Theweld 3401 comprises a weld length, or depth, labeled by 3402. The welddepth 3402 is about 0.030 inches, for example. Notably, the weld 3401does not penetrate the anvil 3400 to the horizontal surfaces of theledges 3417, 3424 and, with this arrangement, the anvil body 3410 willtend to rotationally deflect about the pivot axis P. Specifically, thecombination of forces applied to the anvil body 3410 by the firingmember and the tissue can generate deflection represented by deflection3433. As the firing member cams the anvil 3400 toward the opposingstaple cartridge by pressing on the ledges 3415, represented bydistributed load force 3431, and the tissue and the staple cartridgepush on the tissue-facing surface 3411, represented by distributed loadforce 3432, both sides of the anvil body 3410 (only one shown in FIG.76) may tend to rotate about the pivot axis P. However, the angled weldsurfaces will tend to compress as both sides of the anvil body 3410rotate which may limit the amount of deflection that the anvil 3400experiences. The anvil body 3410 and the anvil cap 3420 may tend tocompress at a non-welded portion 3404 having a length 3403, resulting ina very strong interconnection between the cap 3420 and the body 3410.

FIG. 77 depicts a surgical stapling anvil 3500 for use with a surgicalstapling instrument. The anvil 3500 comprises an anvil body 3510 and ananvil cap 3520. The anvil body 3510 comprises a tissue-facing surface3511 comprising a plurality of staple-forming pockets 3512 definedtherein, ledges 3515 comprising camming surfaces 3516 configured to beengaged by anvil-camming features of a firing member of the surgicalstapling instrument, and a longitudinal slot 3513 configured to receivea firing member therethrough. The ledges 3415 are configured to bear, orsupport, a distributed load force applied by a firing member as thefiring member moves through a staple-firing stroke. The anvil body 3510further comprises ledges 3517 configured to hold the anvil cap 3520 inplace during welding. The ledge 3517 can aid in assembling the cap 3520and the anvil body 3510 and can ensure the proper alignment of the anvilcap 3520 and the anvil body 3510. The ledge 3517 can also improve theoverall stiffness of the anvil 3500. The anvil cap 3520 comprises anupper portion 3523, a lower portion 3521, and ledges 3524 configured torest on the ledges 3517 before, during, and after welding.

The upper portion 3523 of the anvil cap 3520 and the anvil body 3510 arewelded together with welds 3501. Only one weld 3501 is illustrated toprovide clarity of the relationship of the anvil body 3510 and the anvilcap 3520 before and after welding. In this instance, the weld surfacesof the anvil body 3510 and the anvil cap 3520 are angled and, as aresult, the welds 3501 are angled. Each weld 3501 comprises a weldlength, or depth, labeled by 3502. The weld depth, or penetration, 3502can be between about 0.015 inches and about 0.040 inches. In certaininstances, the weld depth is 0.030 inches, for example. Notably, thewelds 3501 penetrate the anvil 3500 to the horizontal surfaces of theledges 3517, 3524. Providing angled weld surfaces that are configured tomatch weld penetration depth can aid in preventing anvil deflectionrotationally as well as vertically. In other words, having welds with aweld penetration depth equal to or greater than that of the length ofthe angled weld surfaces can increase the moment of inertia and theoverall stiffness of the anvil 3500. In other instances, the weld depth3502 may be less than the length of the angled weld surfaces, or matedlength. Suitable welding techniques are used to weld any of the anvilsdisclosed herein. In some instances a gap is present between adjacentweld surfaces which is configured to receive weld material. In someinstances, a gap is not provided. In at least one such instance, theangled weld surfaces are laser welded.

FIG. 78 is a micrograph of an anvil 3600 comprising an anvil bodyportion 3610 and an upper anvil portion 3620. The anvil body portion3610 comprises a tissue-facing surface 3611 comprising a plurality ofstaple forming pockets 3612 defined therein, a longitudinal cavity 3613configured to receive a firing member of a surgical instrumenttherethrough, and ledges 3615 configured to be engaged by a firingmember during a staple firing stroke. The anvil body portion 3610 andthe upper anvil portion 3620 are welded to each other with welds3601—each comprising a weld penetration length 3602. Notably, the welds3601 do not penetrate the anvil 3600 to the horizontal surfaces 3617 ofthe upper ledges 3616 of the anvil body portion 3610.

The anvil 3600 comprises a massive non-welded width 3606 and, also, amassive a slot cavity width 3605. The non-welded width 3606 is about125% of the cavity width 3605. The non-welded width 3606 is so wide, infact, that the intermediate forming pocket rows 3612B and the innerforming pocket rows 3612A are defined within the non-welded width 3606.Similarly, the inner forming pockets 3612A and a portion of theintermediate forming pockets 3612B are defined with the slot cavitywidth 3605. Moreover, an inner boundary axis 3619 of the intermediaterows of forming pockets 3612B is defined within both the non-weldedwidth 3606 and the slot cavity width 3605. Such an arrangement cansignificantly deflect the anvil 3600 when clamping tissue and/or as thefiring member moves through its staple firing stroke. Such deflectionscan be a result of the lack of weld penetration depth as well as arelatively large non-welded width 3605 relative to the slot width 3606.

FIG. 79 depicts an anvil 3700 comprising an anvil body portion 3710 andan anvil cap 3720. The anvil body portion 3710 comprises a planar,tissue-facing surface 3711 including a plurality of staple-formingpockets comprising inner staple-forming pockets 3712A, intermediatestaple-forming pockets 3712B, and outer staple-forming pockets 3712C.The body portion 3710 further comprises a longitudinal cavity, or slot,3713 configured to receive a firing member therethrough, anvil-cammingledges 3715 defining radial cam surfaces 3714 configured to be engagedby a firing member as the firing member moves through its staple-firingstroke, and ledges 3716 configured to hold the anvil cap 3730. The slot3713 comprises a first portion 3713A configured to receive a cuttingmember of the firing member therethrough and a second portion 3713Bconfigured to receive an upper, camming portion of the firing membertherethrough. The first portion 3713A comprises a width that is lessthan the width of the second portion 3713B.

The anvil cap 3720 comprises a Y-shaped cross section. The anvil cap3720 comprises a lower portion 3721 configured to be received within theslot 3713 defining a first mating region and an upper portion 3723configured to be welded to the anvil body 3710. The upper portion 3723comprises ledges, or shoulders, 3724 comprising horizontal alignmentsurfaces configured to rest on corresponding horizontal alignmentsurfaces of the ledges 3716. This interface defines a second matingregion which is perpendicular, or at least substantially perpendicular,to the first mating region. The horizontal alignment surfaces are atleast substantially parallel to the tissue-facing surface 3711. Theupper portion 3723 is flared with respect to the lower portion 3721 andcomprises angled weld surfaces 3725 configured to be welded tocorresponding angled weld surfaces 3717 of the anvil body 3710 defininga third mating region. The welds comprise weld penetration lengths equalto the length of the angled weld surfaces 3725, 3717.

The anvil 3700 comprises a non-welded width 3706 and a slot width 3705.The non-welded width 3706 is no greater than about 105% of the slotwidth 3705. A central plane axis “CA” is defined as the geometric centerof the anvil 3700. The non-welded width 3706, i.e., the width betweenthe welds, defines an outer boundary axis 3731 which is a first distance3731D from the central axis CA. The inner staple-forming pockets 3712Adefine a row axis 3732 which is a second distance 3732D from the centralaxis CA. The second distance 3732D is less than the first distance3731D. As a result, all, or at least a portion of, the innerstaple-forming pockets 3712A are defined within the non-welded width3706. In other instances, the inner staple-forming pockets 3712A arepositioned entirely outside of the non-welded width 3706. In suchinstances, the first width 3731D is less than the second width 3732D. Incertain instances, the outer boundary axis 3731 does not extend beyondan inner boundary axis of the inner staple forming pockets 3712A. Theinner staple-forming pockets 3712A also define an outer boundary axis3733 which is a third distance 3733D from the central axis CA. The thirddistance 3733D is greater than the first distance 3731D and the seconddistance 3732D. In other instances, the inner staple-forming pockets3712A are entirely positioned within the non-welded width 3706. In suchinstances, the second distance 3732D and the third distance 3733D areless than the first distance 3731D.

The intermediate staple-forming pockets 3712B define an inner boundaryaxis 3734 which is a fourth distance 3734D from the central axis. Thefourth distance 3734D is greater than the first distance 3731D, thesecond distance 3732D, and the third distance 3733D. In other words, thenon-welded width 3706 does not extend to the intermediate staple-formingpockets 3712B. Minimizing the first distance 3731D, or the distance thatthe outer boundary axis 3731D extends from the central axis CA, canincrease the overall stiffness of the anvil 3700 to reduce thelongitudinal and rotational, or torsional, bending, or deflection, ofthe anvil 3700.

FIG. 80 is a chart 3800 representing four different surgical staplinganvil arrangements subject to two different load scenarios. Model A is aone-piece, or mono-block, anvil. Model B is a two-piece anvil comprisingan anvil body and an anvil cap welded to the anvil body. The anvil capcomprises an upper welded portion comprising a non-welded width widerthan 105% of the slot width. Like Model B, Model C is a two-piece anvilcomprising an anvil body and an anvil cap welded to the anvil body. Theanvil cap comprises a non-welded width of about 105% of the slot width.However, the angle of the angular weld surfaces, which are definedbetween the anvil cap and the anvil body, of Model C prevents a welddepth from being formed that extends the entire length of the angularweld surfaces. In at least one instance, the weld depth is less than0.03 inches, for example. Model D represents the anvil 3700. The anvilcap comprises a non-welded width of about 105% of the slot width and theangle of the angular weld surfaces of Model D allows a weld depth to becreated that fuses the entire length of the angular weld surfaces. In atleast one instance, the weld depth is at least 0.03 inches, for example.As a result, the distal tip deflection of the anvil 3700 is less thanthe distal tip deflection of the anvils of Model A, Model B, and ModelC. Also, the overall stress in the ledges of Model B, Model C, and ModelD is less than the ledges of Model A.

FIGS. 81-83 depict an anvil 3900 for use with a surgical staplinginstrument. The anvil 3900 is configured to deform staples during asurgical stapling procedure. The anvil 3900 comprises an anvil body 3910and an anvil cap 3920. The anvil body 3910 and the anvil cap 3920 arewelded together. The anvil body 3910 comprises a proximal portion 3912comprising a coupling portion configured to be assembled to an endeffector of a surgical stapling instrument to permit rotation of theanvil jaw 3900 relative to a corresponding jaw such as, for example, astaple cartridge jaw. Embodiments are envisioned where the anvil jaw isfixed relative to the staple cartridge jaw and, in such instance, thestaple cartridge jaw can rotate relative to the anvil jaw. The anvilbody 3910 further comprises a distal tip portion 3914 and a planar,tissue-facing surface 3911. The tissue-facing surface 3911 comprisesstaple-forming pockets 3912 defined therein which are configured todeform staples during a surgical stapling procedure. The anvil body 3910comprises a longitudinal slot 3913 configured to receive a firing memberof the surgical instrument therethrough. The anvil body 3910 furthercomprises camming features 3914 including radial camming surfaces 3915configured to be engaged by anvil-camming portions of the firing memberduring its staple firing stroke.

Referring to FIG. 81, the anvil cap 3920 comprises a plurality ofshallow-weld zones 3930 each comprising a zone length 3930L, and aplurality of deep-weld zones 3940, each comprising a zone length 3940L.The zone lengths 3930L, 3940L are equal; however, in other instances,the zone lengths 3930L, 3940L are different. Each shallow-weld zone 3930of the cap 3920 comprises an upper portion 3933 and a lower portion3931. The upper portions 3933 comprise flared body portions 3934including welding surfaces 3935. The flared body portions 3934 areconfigured to rest on alignment ledges 3916 of the anvil body 3910 whilethe welding surfaces 3935 are configured to engage, or mate, withcorresponding angled welding surfaces 3917 of the anvil body 3910 (FIG.82). Each deep-weld zone 3940 comprises an upper portion 3943 and alower portion 3941. The lower portion 3941 is accessible via a window3945 extending through the upper portion 3943 of the deep weld zone3940. The upper portions 3942 comprise alignment ledges 3944, accessiblevia the weld access region 3945, which are configured to rest oncorresponding alignment ledges 3418 of the anvil body 3910. Thealignment ledges 3916 are first distance from the tissue-facing surface3911 and the alignment ledges 3944 are a second distance from thetissue-facing surface 3911. The first distance is greater than thesecond distance. In other instances, the first distance and the seconddistance are equal.

The welding surfaces 3935, 3917 discussed above are configured to bewelded together to weld the shallow-weld zones 3930 to the anvil body3910 with a weld 3936 comprising a weld root 3937 (FIG. 83). The weldroot 3937 is configured to penetrate at least to the horizontal surfaceof the ledge 3916. The deep-weld zones 3940 are configured to be weldedto the anvil body 3910 with a weld 3946 comprising a weld root 3947(FIG. 83). The weld access region 3945 permits a deep weld, welding thelower portion 3941 to the anvil body 3910. During welding, the entireledge 3946 may be fused with the anvil body 3910. While the weld lengths3938, 3948 may be similar, if not equal, the effective, or net, welddepth between the anvil cap 3920 and the anvil body 3910 increases byproviding both shallow-weld zones 3930 and deep-weld zones 3940. Theweld depth can be defined as the distance between an edge 3921 of anupper surface 3901 of the anvil to the weld root of the respective weld.Alternating the shallow-weld zones 3930 and the deep-weld zones 3940 canpermit shallow and deep welds on both sides of the anvil 3900 along thelongitudinal length of the anvil 3900 and create a robust connectionbetween the anvil cap 3920 and the anvil body 3910.

The shallow-weld zones 3930 and the deep-weld zones 3940 are configuredincrease the overall weld depth along the length of the anvil 3900. Thelocation, longitudinal length, and quantity of shallow-weld zones 3930and deep-weld zones 3940 can be varied to change, or tune, the stiffnessof the anvil 3900 along its length. For example, the shallow-weld zones3930 comprise a first stiffness and the deep-weld zones 3940 comprise asecond stiffness which is different than the first stiffness. Such anarrangement can also permit the use of a single-depth welder to make thewelds 3936, 3946, which can simplify manufacturing. In addition to thesewelds, a filler weld may be applied to fill the access regions 3945after the welds 3946 have been made to increase stiffness of the anvil3900 and reduce the likelihood of rotational deflection within the anvil3900. Embodiments are envisioned where, instead of having longitudinallyalternating zones having deep welds on both sides of the anvil and zoneshaving shallow welds on both sides of the anvil (FIG. 81), the anvilcomprises a plurality of zones extending a length L where each zonecomprises a shallow weld and a deep weld on opposite sides of the anvil.For example, each zone comprises a shallow weld extending along a lengthL of the zone on one side of the anvil and a deep weld extending alongthe length L of the zone on the other side of the anvil. Moreover, inaddition to having different lengths, the plurality of zones mayalternate which side the shallow weld and the deep weld are made. As aresult, such an anvil would comprise of both a shallow weld and a deepweld along the entire length of the anvil.

Various surgical stapling anvils disclosed herein can be manufacturedusing a variety of processes. For example, the anvil body portion and/orthe anvil cap portions can be manufactured using a metal injectionmolding process. The anvil body portion and/or the anvil cap portionscan also be manufactured using a machining process. In at least oneinstance, one of the anvil body portion and the anvil cap ismanufactured using a metal injection molding process and the other oneof the anvil body portion and the anvil cap is entirely manufacturedusing a machining process. In certain instances, electrochemicalmachining processes may be used to form anvil body portion, the anvilcap portion, or both the anvil body portion and the anvil cap portion.Molding processes may permit fillets to be easily incorporated into thegeometries of the anvil cap and/or anvil body. Such fillets can reducestress concentrations at locations where otherwise distinct vertices, orcorners, would exist.

A method for manufacturing a surgical stapling anvil such as thosedisclosed herein may comprise various steps. One step of manufacturingan anvil comprises manufacturing an anvil body portion and an anvil capmember. Another step of manufacturing an anvil comprises polishinganvil-camming surfaces of the anvil body portion. In various instances,any internal surface which may contact any portion of a firing membercan be polished. Another step of manufacturing an anvil compriseswelding the anvil body portion and the anvil cap member together. Thewelding step may comprise, for example, a laser welding process. Yetanother step of manufacturing an anvil comprises stampingstaple-forming, or fastener forming, pockets into a tissue-facingsurface of the anvil body portion.

Further to the above, the polishing step can involve polishing variouszones of the anvil-camming surfaces, or ledges. The ledges can comprisea first zone and a second zone, wherein the first zone is configured tobe contacted by the anvil-camming portions of a firing member and thesecond zone extends laterally beyond the first zone. Under normal firingcircumstances, the firing member would only contact the first ledge zoneand not the second ledge zone. Under abnormal firing circumstances,however, a portion of the firing member may contact the second zone.Thus, it can be advantageous to ensure that both the first zone and thesecond zone of the ledges are polished to reduce the likelihood ofgalling on the ledges when contacted by the firing member.

FIGS. 84 and 85 depict an anvil 4000 comprising an anvil body 4010 andan anvil cap 4020. The anvil body 4010 comprises a tissue-facing surface4011 and a plurality of staple forming pockets 4012 defined in thetissue-facing surface 4011. The anvil 4000 comprises a longitudinalcavity 4013 configured to receive a firing member of surgical instrumenttherethrough. The cavity 4013 comprises anvil-camming surfaces 4015defined by ledges 4014 of the anvil body 4010. The firing member isconfigured to cam the ledges 4014 as the firing member is moved througha firing stroke. The anvil cap 4020 is welded to the anvil body 4010. Awelder, such as a laser welder, for example, is permitted access to theanvil body 4010 and the anvil cap 4020 via welder access regions 4005.The welder access regions 4005 comprise openings, or beveled edges, toprovide space for a welder to access the location to be welded. Largerwelder access regions can ensure deeper weld penetration depth.

The anvil 4000 comprises primary welds 4001 and a secondary filler weld4003. Although only one secondary filler weld 4003 is illustrated, theanvil 4000 may comprise secondary filler weld on top of, or above, allexisting primary welds. The filler weld 4003 provides additionalstiffness to the anvil 4000 over the longitudinal length of the anvil4000 and also aids in preventing rotational skew, or torsional bending,or twist, of the anvil sides. Moreover, the filler weld 4003 increasesthe overall weld penetration depth into the anvil 4000 which increasesthe stiffness of the anvil 4000. The primary welds 4001 fusecorresponding angular surfaces of the anvil body 4010 and the anvil cap4020. More specifically, the anvil body 4010 comprises a first angularsurface 4019 configured to mate with a first angular surface 4029 of theanvil cap 4020, a first horizontal surface 4018 configured to mate witha first horizontal surface 4028 of the anvil cap 4020, a second angularsurface 4017 configured to mate with a second angular surface 4027 ofthe anvil cap 4020, and a second horizontal surface 4016 configured tomate with a second horizontal surface, or bottom surface, 4026 of theanvil cap 4020. During manufacturing, a welder may be selected andconfigured to fuse the first angular surfaces 4019, 4029 together.

The additional angular surfaces 4017, 4027 and the horizontal surfaces4016, 4018, 4026, 4028 are configured to aid the assembly of the anvilbody 4010 and the anvil cap 4020 prior to welding during manufacturing.For example, when preparing the anvil body 4010 and the anvil cap 4020for welding, the additional surfaces may aid in aligning the anvil body4010 and the anvil 4020 for welding. The second horizontal surface 4016provides a defined depth for the anvil cap 4020. In other words, thesecond horizontal surface 4016 defines the lowest, seatable positionthat the bottom surface 4026 can sit relative to the anvil body 4010.

FIG. 86 depicts an anvil 4100 comprising a first anvil member, or anvilbody portion, 4110 and a second anvil member, or anvil cap, 4130. Thefirst anvil member 4110 comprises a tissue-facing surface 4111comprising a plurality of staple-forming pockets 4112 defined therein.The first anvil member 4110 also comprises a longitudinal cavity 4113configured to receive a firing member of a surgical instrumenttherethrough. The first anvil member 4110 further comprisesanvil-camming ledges 4114 defining anvil-camming surfaces 4115configured to be engaged by the firing member as the firing member movesthrough a firing stroke.

The first anvil member 4110 and the second anvil member 4130 compriseinterlocking features configured to increase the overall stiffness ofthe anvil 4100 and reduce transverse, tissue-induced bending of theanvil 4100 away from an opposing staple cartridge when the anvil 4100 isclamped against the staple cartridge. The first anvil member 4110comprises horizontally-extending interlocking features 4117 receivedwithin corresponding interlocking apertures 4137 of the second anvilmember 4130. The first anvil member 4110 also comprisesvertically-extending interlocking features 4116 received withincorresponding apertures 4136 of the second anvil member 4130. In variousinstances, the interlocking features 4116, 4117 may require the anvil4100 to be assembled in only a longitudinal direction prior to beingwelded together. For example, the second anvil member 4130 may be slidlongitudinally relative to the first anvil member in a longitudinaldirection to assemble the first anvil member 4110 and the second anvilmember 4130.

The first anvil member 4110 and the second anvil member 4130 are weldedto each other with exterior welds 4101 and interior welds 4103. Welds4101, 4103 may comprise laser welds, for example. The exterior welds4101 are located in the outer, lateral portions 4105 of the anvil 4100.The interior welds 4103 are located in the longitudinal cavity 4113which is defined by the first anvil member 4110 and the second anvilmember 4130. A laser welder, for example, can access the longitudinalcavity 4113 through the opening, or aperture, defined between thecamming ledges 4114 to form the interior welds 4103. In variousinstances, the opening defined by the camming ledges 4114 is sized topermit welder access specifically for the interior welds 4103. Such anarrangement having interior welds, exterior welds, and interlockingfeatures can increase the overall strength of an anvil as well as reducetransverse deflection and/or torsional deflection. The interlockingfeatures can also provide a fixed holding surface so that, while one ofthe first anvil member and the second anvil member is grounded duringthe weld preparation process, the other one of the first anvil memberand the second anvil member is limited to one plane of motion. Such anarrangement can ensure that the first anvil member and the second anvilmember do not move relative to each other prior to, and/or during, thewelding process.

Referring now to FIG. 87, an anvil 4200 comprises an anvil body 4210 andan anvil cap 4220. The anvil body 4210 comprises a planar,tissue-contacting surface 4211 including a plurality of staple-formingpockets 4212 defined therein. The anvil body 4210 also comprises alongitudinal cavity 4213 configured to receive a firing member of asurgical instrument therethrough. The anvil body 4210 further comprisesanvil-camming ledges 4214 defining anvil-camming surfaces 4215configured to be engaged by the firing member as the firing member movesthrough a firing stroke.

The anvil cap 4220 is positioned within the longitudinal cavity 4213 andis welded to the anvil body 4210 with welds 4201. The welds 4201 maycomprise laser welds, for example. The anvil cap 4220 comprises lateralprojections, or interlocking features, 4221 configured to be receivedwithin apertures 4216 of the anvil body 4210. The welds 4201 comprise aweld depth that does not penetrate into the projections 4221, however,embodiments are envisioned where the welds 4201 extend to theprojections 4221 or into the projections 4221.

FIGS. 88-92 depict a surgical stapling assembly 4300 comprising a weldedanvil which employs another arrangement to aid in the prevention of,and/or the limiting of, the longitudinal bending of the welded anvil.The surgical stapling assembly 4300 comprises an anvil jaw 4340comprising an anvil body 4350 and an anvil cap 4360, a cartridge channeljaw 4330 configured to receive a staple cartridge within acartridge-receiving aperture 4333 thereof, and a closure mechanism 4310configured to pivot the anvil jaw 4340 relative to the cartridge channeljaw 4330 with a cam mechanism. That said, embodiments are envisionedwhere the cartridge channel jaw 4330 is pivoted relative to the anviljaw 4340. The anvil body 4350 comprises a tissue facing surface 4351comprising a plurality of staple forming pockets defined therein whichare configured to deform the staples ejected from a surgical staplecartridge. The stapling assembly 4300 further comprises a firing member4370 configured to move longitudinally within a slot 4357 of the anviljaw 4340 and within a slot 4331 of the cartridge channel jaw 4330 todeploy a plurality of staples stored within a staple cartridge andconfigured to cut tissue captured between the anvil jaw 4340 and thecartridge channel jaw 4330 during a firing stroke.

The surgical stapling assembly 4300 comprises means for improving theoverall stiffness and strength of the anvil jaw 4340 by reducing thestiffness of the cartridge channel jaw 4330. The cartridge channelcomprises channel walls 4334 comprising proximal wall portions 4335 anddistal wall portions 4337. The anvil jaw 4340 is configured to hug, orsurround the cartridge channel jaw 4330, specifically the proximal wallportions 4335, when the anvil jaw 4340 is pivoted toward the cartridgechannel jaw 4330. The anvil body 4350 comprises proximal surroundingportions 4352 configured to hug, or surround, the proximal wall portions4335 as the anvil jaw 4340 is pivoted from an open configuration (FIG.88) into a closed configuration (FIG. 89) by the closure mechanism 4310.The proximal surrounding portions 4352 further comprise tissue stops4359 configured to limit the proximal movement of tissue into thesurgical stapling assembly 4300.

The proximal surrounding portions 4352 comprise a lower portion 4354, anupper portion 4353, and a ledge 4356 defined therebetween. The lowerportions 4354 are configured to overlap the proximal wall portions 4335when the stapling assembly 4300 is in the closed configuration (FIG. 91,e.g.). The upper portions 4353 are thicker, or larger, than the lowerportions 4354; however, the upper portions 4353 and the lower portions4354 can have any suitable configuration. Collectively, the thickerupper portions 4353 and the lower portions 4354 are configured toincrease the overall stiffness and moment of inertia of the anvil jaw4340. The ledges 4336 of the channel jaw 4330 face corresponding ledges4356 of the proximal surrounding portions 4352 when the staplingassembly 4300 is in the closed configuration.

Referring primarily to FIG. 92, the proximal wall portions 4335 comprisea cutout comprising a wall thickness that is less than that of thedistal wall portions 4337. The proximal wall portions 4335 also comprisea smaller height than distal wall portions 4337 (FIG. 91). Providingthinner and smaller walls in the proximal portion of the cartridgechannel jaw 4330 allows for more space for the proximal surroundingportion 4352 of the anvil jaw 4340 to be thicker and, overall, larger,thus increasing the stiffness of the anvil jaw 4340. In previousdesigns, the cartridge channel jaw of a stapling assembly comprised asubstantially greater stiffness than the anvil of the stapling assembly.The present arrangement sacrifices some of the stiffness of thecartridge channel jaw to stiffen the anvil jaw by removing material fromthe cartridge channel jaw and adding the material to the anvil jaw allwhile maintaining a desirable instrument diameter. In various instances,a desired instrument diameter can be 5 mm, 8 mm, or 12 mm, for example.As a result of the above, the proximal surrounding portions 4352comprise a volume of material configured to occupy a void defined as thespace beyond the proximal wall portions 4335 but within the instrumentdiameter.

Further to the above, the anvil jaw 4340 comprises a first stiffness andthe cartridge channel jaw 4330 comprises a second stiffness. Thestapling assembly 4300 comprises structural means for reducing thesecond stiffness to increase the first stiffness. In various instances,the first stiffness and the second stiffness comprise a ratio of betweenabout 1:3 and about 1:1. In some instances, the first stiffness and thesecond stiffness comprise a ratio of about 1:3. In other instances, thefirst stiffness and the second stiffness comprise a ratio of about 1:1.

Referring now to FIGS. 93-95, a cartridge channel jaw 4400 comprises abody portion 4410 and a cap portion 4430. The body portion 4410comprises a longitudinal cavity 4415 (FIG. 94) configured to receive thecap portion 4430. Such an arrangement can permit the polishing ofvarious internal surfaces of the channel jaw 4400 during manufacturingto reduce the force to advance, or fire, a firing member through asurgical instrument. The cartridge channel jaw 4400 comprises a staplecartridge-receiving cavity 4401 defined by channel walls 4411 of thebody portion 4410 which is configured to receive a staple cartridgetherein, a proximal portion 4405 configured to be coupled to aninstrument shaft, and a distal portion 4407. A replaceable staplecartridge is configured to be inserted, or installed, into the cartridgechannel jaw 4400. Referring to FIG. 95, the body portion 4410 furthercomprises a longitudinal aperture 4413 configured to receive a portionof a firing member of a surgical instrument therethrough as the firingmember moves through a staple firing stroke.

The longitudinal cavity 4415 of the body portion 4410 defines ledges4413 (FIG. 95) which are configured to hold the cap portion 4430 inplace relative the body portion 4410 for welding. The cap portion 4430comprises cap walls 4433 and is welded to the body portion 4410 withwelds 4409. The welds 4409 may comprise laser welds, for example. Thecap portion 4430 and the ledges 4413 of the body portion 4410 define alongitudinal slot 4403 configured to slidingly receive a portion of thefiring member. The longitudinal slot 4403 is polished prior to weldingthe cap portion 4430 to the body portion 4410. In various instances, theentirety of the longitudinal slot 4403 is polished. For example, theinternal surfaces of the cap portion 4430 as well as the ledges 4413 arepolished. Polishing the ledges 4413 can be advantageous such that, asthe firing member moves through its staple firing stroke, the polishedledges 4413 can reduce friction between the cartridge channel jaw 4400and the firing member and, therefore, galling of the surfaces whichwould increase the force to fire the surgical instrument. In otherinstances, only certain surfaces of the cap portion 4430 are polished.In such instances, only the horizontal surface 4435 of the cap portion4430 and the ledges 4413 may be polished.

FIGS. 96-107 compare two different firing members 4500, 4600 for usewith surgical stapling systems 4800, 4700, respectively. The firingmember 4500 (FIG. 96) comprises a body 4510 comprising a proximalconnection portion 4512 and a cutting member 4511 configured to cuttissue during a staple-firing stroke. The firing member 4500 furthercomprises a channel jaw-coupling member 4520 and a anvil jaw-couplingmember 4530 configured to hold an anvil jaw and a channel jaw relativeto each other during a staple-firing stroke of the firing member 4500.Similarly, the firing member 4600 (FIG. 97) comprises a body 4610comprising a proximal connection portion 4612, a cutting member 4611configured to cut tissue during a staple-firing stroke, and a lockoutfeature 4615. The firing member 4600 further comprises a channeljaw-coupling member 4620 and a anvil jaw-coupling member 4630 configuredto hold an anvil jaw and a channel jaw relative to each other during astaple-firing stroke of the firing member 4600.

Referring now to FIGS. 98 and 99, the anvil jaw-coupling member 4530 ofthe firing member 4500 comprises lateral projections, or anvil-cammingfeatures, 4531 extending from lateral sides of the body 4510. Theprojections are filleted relative to the body 4510 with fillets 4532.The projections 4531 also comprise outer, rounded corners 4533. Theanvil, jaw-coupling member 4530 defines an upper, planar surface 4534.Each projection 4531 comprises a lateral width, or thickness, 4545 and avertical thickness 4541. The lateral width 4545 is defined as thedistance between the body 4510 and an outer edge 4536 of the projection4531. The lateral projections 4531 define a projection axis 4543 whichis angled at about one degree relative to a horizontal surface of firingmember 4500 such as, for example, an upper camming surface 4521 of thechannel jaw-coupling member 4520. Angling the projections 4531 mayreduce galling of the contact surfaces. The lateral projections 4531further comprise a longitudinal length 4542 (FIG. 102) defined as thedistance between a leading edge 4535 of the projection 4531 and atrailing edge 4537 of the projection 4531.

The longitudinal length 4542 and the vertical thickness 4541 of thelateral projections 4531 comprise a ratio of between about 2.5:1 andabout 20:1, for example. In certain instances, the longitudinal length4542 and the vertical thickness 4541 comprise a ratio of between about5:1 and about 10:1. In some instances, the longitudinal length 4542 andthe vertical thickness 4541 comprise a ratio of about 5:1. In variousinstances, the vertical thickness 4541 and the lateral width 4545comprise a ratio of between about 1:2 and about 1:1, for example. Incertain instances, the vertical thickness 4541 and the lateral width4545 comprise a ratio of about 1:1. These arrangements reduce ledgedeflection and, in turn, reduce the deflection of the projections 4531of the firing member 4500. These arrangements also encourage pure shearas the main source of deflection which increases the ability of theprojections to resist deformation. Arrangements where bending of theprojections is the main source of deflection may result in a greaterlikelihood of plastic deformation of the projections.

Referring now to FIGS. 100 and 101, the anvil jaw-coupling member 4630comprises lateral projections, or anvil-camming features, 4631 extendingfrom lateral sides of the body 4610. Each projection 4631 comprises alateral width, or thickness, 4645 and a vertical thickness 4641. Thelateral width 4645 is defined as the distance between the body 4610 andan outer edge 4636 of the projection 4631. The lateral projections 4631further comprise a longitudinal length 4642 (FIG. 103) defined as thedistance between a leading edge 4635 of the projection 4631 and atrailing edge 4637 of the projection 4631. The longitudinal length 4542is greater than the longitudinal length 4642.

Turning now to FIG. 104, a stapling system 4700 comprises an endeffector for use with a surgical instrument which includes an anvil jaw4750, a cartridge channel jaw 4780, and a staple cartridge 4710installed within the cartridge channel jaw 4780. The stapling system4700 also comprises the firing member 4600, discussed above. The staplecartridge 4710 comprises a plurality of staples removably stored withinstaple cavities 4712 of the staple cartridge 4710 configured to be firedby the firing member 4600, a cartridge deck, or tissue-facing surface,4711, and a longitudinal slot 4713 configured to receive the firingmember 4600 therethrough. The anvil jaw 4750 comprises a tissue-facingsurface 4751 comprising a plurality of staple-forming pockets 4752configured to deform the staples, an anvil slot 4753 configured toreceive the jaw-coupling member 4630 of the firing member 4600therethrough, and camming ledges 4755 configured to be engaged by theprojections 4631 of the firing member 4600 as the firing member 4600moves through its staple firing stroke. The channel 4780 compriseschannel walls 4781, a longitudinal slot, or cavity, 4785 configured toreceive the jaw-coupling member 4620 therethrough, and camming ledges4783 configured to be engaged by the jaw-coupling member 4620 as thefiring member 4600 moves through its staple-firing stroke. In thisscenario, the projections 4631 act as cantilever beams resulting in muchless force required to bend the projections 4631 than in the systemdescribed below.

Turning now to FIG. 105, a stapling system 4800 comprises an endeffector for use with a surgical instrument comprising the anvil jaw3700, the cartridge channel jaw 4400, and a staple cartridge 4810installed within the cartridge channel jaw 4400. The system 4800 alsocomprises the firing member 4500. The staple cartridge 4810 comprises aplurality of staples removably stored within staple cavities 4812 of thestaple cartridge 4810 configured to be fired by the firing member 4500,a cartridge deck, or tissue-facing surface, 4811, and a longitudinalslot 4813 configured to receive the firing member 4500 therethrough. Theanvil slot 3713 is configured to receive the jaw-coupling member 4530 ofthe firing member 4500 therethrough and the camming ledges 3715 areconfigured to be engaged by the projections 4531 as the firing member4500 moves through its staple firing stroke. In such instances, therounded edges 4533 of the projections 4531 are configured to engage theradiused portions 3714 of the camming ledges 3715. The longitudinal slot4403 of channel jaw 4400 is configured to receive the jaw-couplingmember 4520 therethrough and the camming ledges 4413 are configured tobe engaged by the jaw-coupling member 4520 as the firing member 4500moves through its staple-firing stroke. In this scenario, the mainsource of deflection of the projections 4531 is caused by shear stressrequiring a much greater force to deform the projections 4531 than theforce required to deform the projections 4631 of the system 4700illustrated in FIG. 104.

Turning now to FIGS. 106 and 107, a comparison of the deflection of theledges of each stapling system 4700, 4800 is illustrated. An identicalfiring load is applied to the stapling systems 4700, 4800 illustrated inFIGS. 106 and 107. In FIG. 106, the system 4800 is illustrated with adeflection 4801. In FIG. 107, the system 4700 is illustrated with adeflection 4701 which is greater than the deflection 4801. Thisdifference can be due, in part, to the lack of stiffness of theprojections 4631, the geometry of the ledges 4755 and their lack ofability to resist bending, the increased stiffness of the projections4531, and/or the geometry of the ledges 3715 and their ability to resistbending, among other things. For instance, the stapling system 4800places the projections 4531 and the ledges 3715 primarily in shearincreasing their ability to resist deformation. Moreover, rounding theprojections and shortening the width of the projections of the firingmember increases stiffness of the corresponding jaw-coupling member aswell as the anvil due to the fact that more material of the anvil ispermitted.

In certain instances, balancing the stiffnesses of the ledge 3715 andthe projections 4531 will balance the magnitude of deflection of theledge 3715 and the magnitude of deflection of the projection 4531 duringa firing stroke of the firing member. As a result of such balanceddeflections, neither the ledge nor the projection will dominate eachother in terms of deflection and, thus, neither the ledge nor theprojection will cause the other to plastically deform substantially morethan the other and possibly not at all, during the firing stroke. Invarious instances, the stiffness of the ledge is equal to, substantiallyequal to, or less than the stiffness of the projection. In certaininstances, the height, or vertical thickness, of the ledge issubstantially similar to the height, or vertical thickness, of theprojection. In addition to, or in lieu of, providing balanced geometriesof the ledge and the projection, the materials of the ledge and theprojection can be selected based on yield strength and/or hardnessvalues, for example. Having materials with similar yield strengthsand/or hardness values of the materials can encourage equal, orbalanced, deflection of the ledge and the projection.

FIG. 108 is a stress and strain analysis 4900 of the anvil 3700comprising a weld 3701 during the advancement of the firing member 4500.As can be seen in FIG. 108, the combination of the application of adistributed load 4903 by the firing member 4500 to the ledges 3715 andthe application of a distributed load 4905 by the tissue and cartridge4810 to the tissue-facing surface 3711 results in a deflection 4901 anda stress profile as illustrated. The stress analysis shows low stressregions 4907, medium stress regions 4908, and high stress regions 4909.Notably, the stress at and near the weld 3701 is evenly distributed anddoes not localize, or concentrate, at or near the weld 3701.

In various designs, a T-shaped cutter bit is used to machine the slot inthe anvil and/or channel that receives the jaw-coupling members of afiring member. This method of machining can cause bit chatter which canroughen the surface of the slots cut with the T-shaped cutter bit. Intwo-piece anvil and channel designs, a standard cutter bit can be usedeliminating this issue to provide a better surface finish and resultingin a reduced force to fire the firing member.

Another way to reduce the force to fire may include coating at least thepolished surfaces of the anvil with a material to reduce the coefficientof friction of those surfaces. Such a coating can comprise Medcoat 2000,for example.

During manufacturing of various welded anvil designs disclosed herein,x-ray techniques may be employed to verify weld depth and/or weldintegrity to reduce faulty resultant welds from passing a qualitycontrol test lacking an x-ray step. Another quality control step mayinclude a batch destructive test where an anvil is sliced and thenanalyzed to ensure proper weld depth and/or weld integrity.

Various materials to increase strength and/or provide desirable weldmaterials may be used in the manufacturing of various two-piece anvildesigns disclosed herein. For example, a Tungsten-rhenium alloy may beused for the anvil cap material. In various instances, a W-3, W-5, W-25,or W-26 Tungsten-rhenium alloy may be used for the anvil cap material.In some instances, a silver-nickel clad may be used for the anvil capand a 416 stainless steel or 17-4 stainless steel may be used for theanvil body, for example.

As discussed above, the anvil body and the anvil cap may comprisedifferent materials. These materials can be selected based onweldability and/or strength, for example. In addition to weldability andstrength, another material selection process may factor in hardness.This can be particularly important for the anvil-camming ledges of theanvil body. In some instances, the material selected for the anvil bodycan comprise of a hardness value which is greater than the hardnessvalue of the anvil cap. The anvil-camming ledges may then be lessresistant to galling than if the anvil body and the anvil cap were bothmanufactured using a softer material.

In certain instances, the rows of forming pockets may be stamped intothe tissue-facing surface of the anvil. In such instances, a slit, ornotch, may be cut into the tissue-facing surface to provide space formaterial to move toward, or into, during the stamping process. This maypermit all of the forming pocket rows to comprise forming pockets havingequal pocket depths where stamping the pockets without the precut slitmay make equal pocket depths amongst the rows difficult.

EXAMPLES Example 1

A surgical stapling anvil for use with a surgical instrument, whereinthe surgical stapling anvil comprises an anvil body comprising atissue-facing surface comprising a plurality of staple-forming pocketsdefined therein and a longitudinal cavity defined therein. Thelongitudinal cavity comprises a first cavity portion comprising a firstwidth, wherein the first cavity portion is configured to receive atleast a portion of a cutting edge of a firing member of the surgicalinstrument therethrough, a second cavity portion comprising a secondwidth which is greater than the first width, wherein the second cavityportion is configured to receive an anvil-engaging portion of the firingmember therethrough, and a third cavity portion comprising a third widthwhich is greater than the second width, wherein the third cavity portionfurther comprises a first angular surface which flares outward relativeto the second cavity portion. The anvil further comprises an anvil capcomprising a first section positioned within a portion of the secondcavity portion and a second section positioned within the third cavityportion, wherein the second section comprises a second angular surfacecorresponding to the first angular surface, and wherein a mated portionof the first angular surface and the second angular surface define amated depth. The anvil further comprises a weld welding the firstangular surface and the second angular surface together, wherein theweld comprises a weld depth which is substantially equal to the mateddepth.

Example 2

The surgical stapling anvil of Example 1, wherein the anvil capcomprises a Y-shaped cross section.

Example 3

The surgical stapling anvil of Examples 1 or 2, wherein the weld depthis between about 0.015 inches and about 0.040 inches.

Example 4

The surgical stapling anvil of Example 3, wherein the weld depth is0.030 inches.

Example 5

The surgical stapling anvil of Examples 1, 2, 3, or 4, wherein the thirdcavity portion comprises a first ledge surface, wherein the secondsection comprises a second ledge surface corresponding to the firstledge surface, and wherein the first ledge surface and the second ledgesurface are at least substantially parallel to the tissue-facingsurface.

Example 6

The surgical stapling anvil of Example 5, wherein the weld extends intothe ledge surfaces.

Example 7

The surgical stapling anvil of Examples 1, 2, 3, 4, 5, or 6, wherein theweld comprises a laser weld.

Example 8

The surgical stapling anvil of Examples 1, 2, 3, 4, 5, 6, or 7, whereinthe weld depth is less than the mated depth.

Example 9

The surgical stapling anvil of Examples 1, 2, 3, 4, 5, 6, or 7, whereinthe weld depth is greater than the mated depth.

Example 10

A surgical stapling anvil for use with a surgical instrument, whereinthe surgical stapling anvil comprises a first anvil member comprising atissue-facing surface comprising a plurality of staple-forming pocketsdefined therein and a longitudinal cavity. The longitudinal cavitycomprises a first cavity portion comprising a first width, wherein thefirst cavity portion is configured to receive at least a portion of acutting edge of a firing member of the surgical instrument therethrough,a second cavity portion comprising a second width which is greater thanthe first width, wherein the second cavity portion is configured toreceive an anvil-engaging portion of the firing member therethrough, anda third cavity portion comprising a third width which is greater thanthe second width. The anvil further comprises a second anvil membercomprising a first section positioned within the second cavity portion,a second section positioned within the third cavity portion, wherein thesecond section comprises a fourth width which is greater than the secondwidth, and a transition edge, wherein the first section and the secondsection transition at the transition edge. The anvil further comprises aweld connecting the second section and the first anvil member together,wherein the weld extends at least to the transition edge.

Example 11

The surgical stapling anvil of Example 10, wherein the second sectionflares outwardly relative to the first section.

Example 12

The surgical stapling anvil of Examples 10 or 11, wherein the secondanvil member comprises a Y-shaped cross section.

Example 13

The surgical stapling anvil of Examples 10, 11, or 12, wherein the weldcomprises a weld depth of between about 0.015 inches and about 0.040inches.

Example 14

The surgical stapling anvil of Examples 10, 11, 12, or 13, wherein thetransition edge comprises a ledge surface at least substantiallyparallel to the tissue-facing surface.

Example 15

The surgical stapling anvil of Example 14, wherein the weld extends intothe ledge surface.

Example 16

The surgical stapling anvil of Examples 10, 11, 12, 13, 14, or 15,wherein the weld comprises a laser weld.

Example 17

A surgical stapling anvil comprising a first anvil member comprising alongitudinal slot configured to receive a firing member of a surgicalinstrument therethrough and a tissue-facing surface comprising aplurality of staple-forming pockets defined therein. The anvil furthercomprises a second anvil member and a weld welding the first anvilmember and the second anvil member together, wherein the first anvilmember and the second anvil member comprise first mating surfaces atleast substantially perpendicular to the tissue-facing surface, andsecond mating surfaces angled relative to the tissue-facing surface,wherein the weld connects at least the second mating surfaces together.

Example 18

The surgical stapling anvil of Example 17, wherein the weld alsoconnects at least a portion of the first mating surfaces together.

Example 19

The surgical stapling anvil of Examples 17 or 18, wherein the firstanvil member and the second anvil member further comprise third matingsurfaces at least substantially parallel to the tissue-facing surface.

Example 20

The surgical stapling anvil of Example 19, wherein the second matingsurfaces and the third mating surfaces are configured to aid in holdingthe second anvil member relative to the first anvil member for welding.

Example 21

The surgical stapling anvil of Examples 19 or 20, wherein the weld alsowelds at least a portion of the third mating surfaces together.

Example 22

The surgical stapling anvil of Examples 17, 18, 19, or 20, or 21,wherein the second mating surfaces comprise a mated depth which at leastsubstantially matches a predetermined weld depth of a welder used toweld the second mating surfaces together.

Example 23

The surgical stapling anvil of Examples 17, 18, 19, 20, 21, or 22,wherein the weld comprises a weld depth of between about 0.015 inchesand about 0.040 inches.

Example 24

A surgical stapling anvil comprising an anvil body comprising atissue-facing surface, a plurality of staple forming pockets defined inthe tissue-facing surface, and a longitudinal slot. The longitudinalslot comprises a first portion comprising a first width, wherein thefirst portion is configured to receive a cutting edge of a firing membertherethrough, and a second portion comprising a second width greaterthan the first width, wherein the second portion is configured toreceive an anvil-camming portion of the firing member therethrough. Theanvil further comprises an anvil cap welded to the anvil body, whereinthe anvil cap comprises a welded portion and a non-welded portion,wherein the non-welded portion comprises a non-welded width, and whereinthe non-welded width is less than or equal to about 105% of the secondwidth.

Example 25

The surgical stapling anvil of Example 24, wherein the non-weldedportion comprises a first non-welded portion configured to be receivedwithin the second portion of the longitudinal slot and a secondnon-welded portion comprising alignment surfaces configured to align theanvil cap to the anvil body for welding.

Example 26

The surgical stapling anvil of Example 25, wherein the tissue-facingsurface defines a first plane, and wherein the alignment surfaces definea second plane at least substantially parallel to the first plane.

Example 27

The surgical stapling anvil of Examples 24, 25, or 26, wherein thewelded portion is flared with respect to the non-welded portion.

Example 28

The surgical stapling anvil of Examples 24, 25, 26, or 27, wherein thewelded portion comprises welded, angular surfaces corresponding toangular surfaces of the anvil body.

Example 29

The surgical stapling anvil of Examples 24, 25, 26, 27, or 28, whereinthe anvil cap comprises a Y-shaped cross-section.

Example 30

A surgical stapling anvil, comprising an anvil body comprising alongitudinal slot defining a slot axis, wherein the longitudinal slotcomprises slot surfaces facing each other, and a tissue-facing surface.The tissue-facing surface comprises a first side and a second sidedefined by the longitudinal slot, and a plurality of staple-formingpockets arranged in a plurality of longitudinal rows of staple-formingpockets, wherein the plurality of longitudinal rows of staple-formingpockets comprises an inner-most row of staple-forming pockets closest tothe longitudinal slot, wherein the inner-most row of staple-formingpockets defines a row axis a first distance from the slot axis and afirst outer boundary axis a second distance from the slot axis which isgreater than the first distance. The anvil further comprises an anvilcap welded to the anvil body. The anvil cap comprises a welded portionand a non-welded portion comprising an outer-most non-welded regiondefining a second outer boundary axis positioned a third distance fromthe slot axis, wherein the third distance is less than the seconddistance.

Example 31

The surgical stapling anvil of Example 30, wherein the third distance isgreater than the first distance.

Example 32

The surgical stapling anvil of Example 30, wherein the third distance isless than the first distance.

Example 33

The surgical stapling anvil of Examples 30, 31, or 32, wherein the anvilcap further comprises alignment surfaces configured to align the anvilcap to the anvil body for welding.

Example 34

The surgical stapling anvil of Example 33, wherein the tissue-facingsurface defines a first plane, and wherein the alignment surfaces definea second plane at least substantially parallel to the first plane.

Example 35

The surgical stapling anvil of Examples 30, 31, 32, 33, or 34, whereinthe welded portion is flared with respect to the non-welded portion.

Example 36

The surgical stapling anvil of Examples 30, 31, 32, 33, 34, or 35,wherein the welded portion comprises welded, angular surfacescorresponding to angular surfaces of the anvil body.

Example 37

The surgical stapling anvil of Examples 30, 31, 32, 33, 34, 35, or 36,wherein the anvil cap comprises a Y-shaped cross-section.

Example 38

An anvil for use with a surgical instrument, wherein the anvil comprisesa first anvil member comprising a tissue-facing surface defining a datumplane and a plurality of staple forming pockets defined in thetissue-facing surface. The anvil further comprises a second anvil memberwelded to the first anvil member by at least one weld. The first anvilmember and the second anvil member comprise a first mating regiondefining a first plane which is at least substantially parallel to thedatum plane, a second mating region defining a second plane which is atleast substantially perpendicular to the datum plane, and a third matingregion defining a third plane which is angled relative to the datumplane, wherein the first anvil member and the second anvil member arewelded by the at least one weld at the third mating region.

Example 39

The anvil of Example 38, wherein the third mating region comprises alength, and wherein the at least one weld comprises a weld penetrationdepth which is at least about equal to the length.

Example 40

The anvil of Example 39, wherein the weld penetration depth is greaterthan the length.

Example 41

The anvil of Examples 38, 39, or 40, wherein the first mating regioncomprises alignment surfaces configured to align the first anvil memberand the second anvil member for welding.

Example 42

The anvil of Examples 38, 39, 40, or 41, wherein the second anvil membercomprises a Y-shaped cross-section.

Example 43

The anvil of Examples 38, 39, 40, 41, or 42, wherein the at least oneweld comprises a laser weld.

Example 44

A surgical stapling anvil comprising an anvil body comprising alongitudinal slot configured to receive a firing member therethrough anda tissue-facing surface comprising a plurality of staple-forming pocketsdefined therein. The anvil further comprises an anvil cap and aplurality of welds welding the anvil cap and the anvil body together.the welds comprise a shallow-welded zone comprising a first weld depthand a deep-welded zone comprising a second weld depth which is differentthan the first weld depth, wherein the shallow-welded zone and thedeep-welded zone are configured to increase the net weld depth of theplurality of welds.

Example 45

The surgical stapling anvil of Example 44, wherein the anvil cap and theanvil body comprise corresponding alignment features configured to aidin aligning the anvil body and the anvil cap for welding.

Example 46

The surgical stapling anvil of Example 45, wherein the correspondingalignment features comprise a first alignment feature on a first side ofthe longitudinal slot positioned a first distance from the tissue-facingsurface and a second alignment feature on a second side of thelongitudinal slot positioned a second distance from the tissue-facingsurface, and wherein the first distance and the second distance aredifferent.

Example 47

The surgical stapling anvil of Examples 44, 45, or 46, wherein thedeep-welded zone comprises a first longitudinal length, wherein theshallow-welded zone comprises a second longitudinal length, and whereinthe first longitudinal length and the second longitudinal length aredifferent.

Example 48

The surgical stapling anvil of Examples 44, 45, 46, or 47, wherein thedeep-welded zone comprises a first longitudinal length, wherein theshallow-welded zone comprises a second longitudinal length, and whereinthe first longitudinal length and the second longitudinal length overlapeach other along a length of the surgical stapling anvil.

Example 49

The surgical stapling anvil of Examples 44, 45, 46, 47, or 48, whereinthe deep-welded zone comprises a welder access region.

Example 50

The surgical stapling anvil of Example 49, wherein the welder accessregion comprises a filler weld.

Example 51

The surgical stapling anvil of Examples 44, 45, 46, 47, 48, 49, or 50,wherein the shallow-welded zone comprises a first stiffness, wherein thedeep-welded zone comprises a second stiffness, and wherein the firststiffness and the second stiffness are different.

Example 52

The surgical stapling anvil of Examples 44, 45, 46, 47, 48, 49, 50, or51, wherein the anvil body and the anvil cap are manufactured using ametal injection molding process.

Example 53

A surgical stapling anvil comprising a first anvil member comprising alongitudinal slot configured to receive a firing member therethrough, atissue-facing surface comprising a plurality of staple-forming pocketsdefined therein, and an upper anvil surface, wherein the upper anvilsurface comprises an aperture defining an edge of the first anvilmember. The anvil further comprises a second anvil member and a weldconfiguration welding the first anvil member and the second anvil membertogether. The weld configuration comprises a first weld comprising afirst weld depth comprising a first weld root, wherein the first welddepth is defined as the distance between the edge and the first weldroot, and a second weld comprising a second weld depth comprising asecond weld root, wherein the second weld depth is defined as thedistance between the edge and the second weld root, wherein the secondweld depth and the first weld depth are different, and wherein the firstweld and the second weld are configured to increase the net weld depthof the weld configuration.

Example 54

The surgical stapling anvil of Example 53, wherein the first anvilmember and the second anvil member comprise corresponding alignmentfeatures configured to aid in aligning the first anvil member and thesecond anvil member for welding.

Example 55

The surgical stapling anvil of Example 54, wherein the correspondingalignment features comprise a first alignment feature on a first side ofthe longitudinal slot positioned a first distance from the tissue-facingsurface and a second alignment feature on a second side of thelongitudinal slot positioned a second distance from the tissue-facingsurface, and wherein the first distance and the second distance aredifferent.

Example 56

The surgical stapling anvil of Examples 53, 54, or 55, wherein the firstweld comprises a first longitudinal length, wherein the second weldcomprises a second longitudinal length, and wherein the firstlongitudinal length and the second longitudinal length are different.

Example 57

The surgical stapling anvil of Examples 53, 54, 55, or 56, wherein thefirst weld comprises a first longitudinal length, wherein the secondweld comprises a second longitudinal length, and wherein the firstlongitudinal length and the second longitudinal length overlap eachother along a length of the surgical stapling anvil.

Example 58

The surgical stapling anvil of Examples 53, 54, 55, 56, or 57, furthercomprising a filler weld positioned on the first weld.

Example 59

The surgical stapling anvil of Examples 53, 54, 55, 56, 57, or 58,further comprising a first stiffness along the first weld and a secondstiffness along the second weld, wherein the first stiffness and thesecond stiffness are different.

Example 60

The surgical stapling anvil of Examples 53, 54, 55, 56, 57, 58, or 59,wherein the first anvil member and the second anvil member aremanufactured using a metal injection molding process.

Example 61

A surgical stapling anvil comprising an anvil body comprising atissue-facing surface comprising a plurality of staple-forming pockets,and an interlocking aperture. The anvil further comprises an anvil cap,wherein the anvil body and the anvil cap are welded together, andwherein the anvil cap comprises an interlocking feature configured to bereceive within the interlocking aperture.

Example 62

The surgical stapling anvil of Example 61, wherein the anvil bodyfurther comprises a longitudinal slot configured to receive a firingmember of a surgical instrument therethrough, wherein the longitudinalslot defines a longitudinal axis, and wherein the anvil body and theanvil cap can only be assembled along the longitudinal axis.

Example 63

The surgical stapling anvil of Examples 61 or 62, wherein the anvil bodyand the anvil cap are manufactured using a metal injection moldingprocess.

Example 64

A surgical stapling assembly comprising a shaft defining a shaft axis, afirst jaw comprising a staple cartridge channel, a staple cartridgecomprising a plurality of staples removably stored therein, and an anvilconfigured to deform the staples. The anvil comprises a tissue-facingsurface, a plurality of staple-forming pockets defined in thetissue-facing surface, and a longitudinal slot. The anvil furthercomprises a firing member comprising a body portion comprising a firstlateral side and a second lateral side, a cutting member, achannel-engaging portion configured to slidably engage the first jaw asthe firing member moves through a staple-firing stroke, and ananvil-engaging portion configured to slidably engage the anvil as thefiring member moves through a staple-firing stroke, wherein theanvil-engaging portion comprises lateral portions extending from thebody portion, wherein the lateral portions define an anvil-engagingportion axis that is angled relative to the shaft axis, wherein thelateral portions comprise a longitudinal length and a verticalthickness, and wherein the longitudinal length and the verticalthickness comprise a ratio between about 2.5:1 and about 20:1.

Example 65

The surgical stapling assembly of Example 64, wherein the ratio isbetween about 5:1 and about 10:1.

Example 66

The surgical stapling assembly of Example 64, wherein the ratio is about5:1.

Example 67

The surgical stapling assembly of Examples 64, 65, or 66, wherein eachlateral portion and body portion comprise a fillet therebetween.

Example 68

The surgical stapling assembly of Examples 64, 65, 66, or 67, whereinthe lateral portions comprise rounded outer ends.

Example 69

The surgical stapling assembly of Examples 64, 65, 66, 67, or 68,wherein the anvil-engaging portion comprises a planar upper surface.

Example 70

The surgical stapling assembly of Examples 64, 65, 66, 67, 68, or 69,wherein each lateral portion comprises a rounded leading edge.

Example 71

The surgical stapling assembly of Examples 64, 65, 66, 67, 68, 69, or70, wherein the anvil-engaging portion axis is angled at about onedegree relative to the shaft axis.

Example 72

A surgical stapling assembly comprising a shaft defining a shaft axis, afirst jaw comprising a staple cartridge channel, a staple cartridgecomprising a plurality of staples removably stored therein, and a secondjaw comprising an anvil, wherein the anvil is configured to deform thestaples. The anvil comprises a tissue-facing surface, a plurality ofstaple-forming pockets defined in the tissue-facing surface, and alongitudinal slot. The stapling assembly further comprises a firingmember comprising a vertically extending body portion comprising twolateral sides, a first jaw engagement member configured to slidablyengage the first jaw as the firing member moves through a staple-firingstroke, and a second jaw engagement member extending laterally from eachlateral side of the body portion, wherein the second jaw engagementmember is oriented at an angle relative to the shaft axis, wherein thesecond jaw engagement member is configured to slidably engage the secondjaw as the firing member moves through the staple-firing stroke. Thesecond jaw engagement member comprises a vertical thickness and alateral width defined as the distance between the body portion and anouter edge of the second jaw engagement member, and wherein the verticalthickness and the lateral width comprise a ratio between about 1:2 andabout 1:1.

Example 73

The surgical stapling assembly of Example 72, wherein the ratio is about1:1.

Example 74

The surgical stapling assembly of Examples 72 or 73, wherein the secondjaw engagement member and the body portion comprise a fillettherebetween.

Example 75

The surgical stapling assembly of Examples 72, 73, or 74, wherein thesecond jaw engagement member comprises rounded outer ends.

Example 76

The surgical stapling assembly of Examples 72, 73, 74, or 75, whereinthe second jaw engagement member comprises a planar upper surface.

Example 77

The surgical stapling assembly of Examples 72, 73, 74, 75, or 76,wherein the second jaw engagement member comprises rounded leadingedges.

Example 78

The surgical stapling assembly of Examples 72, 73, 74, 75, 76, or 77,wherein the second jaw engagement member is oriented at an angle ofabout one degree relative to the shaft axis.

Example 79

A surgical stapling assembly comprising a shaft defining a shaft axis, afirst jaw comprising a staple cartridge channel, a staple cartridgecomprising a plurality of staples removably stored therein, and a secondjaw comprising an anvil, wherein the anvil is configured to deform thestaples. The anvil comprises a tissue-facing surface, a plurality ofstaple-forming pockets defined in the tissue-facing surface, and alongitudinal slot. The stapling assembly further comprises a firingmember comprising a body portion comprising a first lateral side and asecond lateral side, a cutting member, a first jaw-coupling memberconfigured to slidably engage the first jaw as the firing member movesthrough a staple-firing stroke, and a second jaw-coupling memberconfigured to slidably engage the anvil as the firing member movesthrough a staple-firing stroke, wherein the second jaw-coupling membercomprises lateral portions extending from the first lateral side and thesecond lateral side and defining a planar upper surface, wherein thesecond jaw-coupling member is angled relative to the shaft axis, whereinthe lateral portions and the lateral sides comprise filletstherebetween, and wherein the lateral portions comprise rounded outerends.

Example 80

The surgical stapling assembly of Example 79, wherein each lateralportion comprises a rounded leading edge.

Example 81

The surgical stapling assembly of Examples 79 or 80, wherein thelongitudinal slot comprises rounded slot edges defining an opening ofthe longitudinal slot, and wherein the fillets are configured toslidably engage the rounded slot edges.

Example 82

The surgical stapling assembly of Examples 79, 80, or 81, wherein thelongitudinal slot comprises rounded, lateral slot portions, and whereinthe rounded outer ends are configured to slidably engage thecorresponding rounded slot portions.

Example 83

The surgical stapling assembly of Examples 79, 80, 81, or 82, whereinthe second jaw-coupling member is angled at about one degree relative tothe shaft axis.

Example 84

A surgical instrument assembly comprising a firing member comprising ananvil-camming portion comprising a first stiffness, a staple cartridgecomprising a plurality of staples configured to be ejected from thestaple cartridge by the firing member, and an anvil. The anvil comprisesa tissue-facing surface comprising a plurality of staple forming pocketsconfigured to deform the staples, and an anvil ledge configured to beengaged by the anvil-camming portion of the firing member during afiring stroke, wherein the anvil ledge comprises a second stiffness, andwherein the second stiffness is substantially equal to the firststiffness such that the deflection of the anvil ledge would besubstantially equal to the deflection of the anvil-camming portion.

Example 85

The surgical instrument assembly of Example 84, further comprising meansfor balancing the first stiffness and the second stiffness.

Example 86

The surgical instrument assembly of Example 85, wherein the meanscomprises an adjustment to at least one of a first geometry of theanvil-camming portion and a second geometry of the anvil ledge toprovide substantially similar stiffnesses.

Example 87

The surgical instrument assembly of Examples 85 or 86, wherein the meansfurther comprises adjusting at least one of a first height of theanvil-camming portion and a second height of the anvil ledge to providesubstantially similar stiffnesses.

Example 88

The surgical instrument assembly of Examples 85, 86, or 87, wherein themeans comprises substantially equating the yield strengths of theanvil-camming portion and the anvil ledge.

Example 89

The surgical instrument assembly of Examples 85, 86, 87, or 88, whereinthe means comprises substantially equating the hardnesses of theanvil-camming portion and the anvil ledge.

Many of the surgical instrument systems described herein are motivatedby an electric motor; however, the surgical instrument systems describedherein can be motivated in any suitable manner. In various instances,the surgical instrument systems described herein can be motivated by amanually-operated trigger, for example. In certain instances, the motorsdisclosed herein may comprise a portion or portions of a roboticallycontrolled system. Moreover, any of the end effectors and/or toolassemblies disclosed herein can be utilized with a robotic surgicalinstrument system. U.S. patent application Ser. No. 13/118,241, entitledSURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENTARRANGEMENTS, now U.S. Pat. No. 9,072,535, for example, disclosesseveral examples of a robotic surgical instrument system in greaterdetail.

The surgical instrument systems described herein have been described inconnection with the deployment and deformation of staples; however, theembodiments described herein are not so limited. Various embodiments areenvisioned which deploy fasteners other than staples, such as clamps ortacks, for example. Moreover, various embodiments are envisioned whichutilize any suitable means for sealing tissue. For instance, an endeffector in accordance with various embodiments can comprise electrodesconfigured to heat and seal the tissue. Also, for instance, an endeffector in accordance with certain embodiments can apply vibrationalenergy to seal the tissue.

The entire disclosures of:

-   -   U.S. Pat. No. 5,403,312, entitled ELECTROSURGICAL HEMOSTATIC        DEVICE, which issued on Apr. 4, 1995;    -   U.S. Pat. No. 7,000,818, entitled SURGICAL STAPLING INSTRUMENT        HAVING SEPARATE DISTINCT CLOSING AND FIRING SYSTEMS, which        issued on Feb. 21, 2006;    -   U.S. Pat. No. 7,422,139, entitled MOTOR-DRIVEN SURGICAL CUTTING        AND FASTENING INSTRUMENT WITH TACTILE POSITION FEEDBACK, which        issued on Sep. 9, 2008;    -   U.S. Pat. No. 7,464,849, entitled ELECTRO-MECHANICAL SURGICAL        INSTRUMENT WITH CLOSURE SYSTEM AND ANVIL ALIGNMENT COMPONENTS,        which issued on Dec. 16, 2008;    -   U.S. Pat. No. 7,670,334, entitled SURGICAL INSTRUMENT HAVING AN        ARTICULATING END EFFECTOR, which issued on Mar. 2, 2010;    -   U.S. Pat. No. 7,753,245, entitled SURGICAL STAPLING INSTRUMENTS,        which issued on Jul. 13, 2010;    -   U.S. Pat. No. 8,393,514, entitled SELECTIVELY ORIENTABLE        IMPLANTABLE FASTENER CARTRIDGE, which issued on Mar. 12, 2013;    -   U.S. patent application Ser. No. 11/343,803, entitled SURGICAL        INSTRUMENT HAVING RECORDING CAPABILITIES; now U.S. Pat. No.        7,845,537;    -   U.S. patent application Ser. No. 12/031,573, entitled SURGICAL        CUTTING AND FASTENING INSTRUMENT HAVING RF ELECTRODES, filed        Feb. 14, 2008;    -   U.S. patent application Ser. No. 12/031,873, entitled END        EFFECTORS FOR A SURGICAL CUTTING AND STAPLING INSTRUMENT, filed        Feb. 15, 2008, now U.S. Pat. No. 7,980,443;    -   U.S. patent application Ser. No. 12/235,782, entitled        MOTOR-DRIVEN SURGICAL CUTTING INSTRUMENT, now U.S. Pat. No.        8,210,411;    -   U.S. patent application Ser. No. 12/249,117, entitled POWERED        SURGICAL CUTTING AND STAPLING APPARATUS WITH MANUALLY        RETRACTABLE FIRING SYSTEM, now U.S. Pat. No. 8,608,045;    -   U.S. patent application Ser. No. 12/647,100, entitled        MOTOR-DRIVEN SURGICAL CUTTING INSTRUMENT WITH ELECTRIC ACTUATOR        DIRECTIONAL CONTROL ASSEMBLY, filed Dec. 24, 2009; now U.S. Pat.        No. 8,220,688;    -   U.S. patent application Ser. No. 12/893,461, entitled STAPLE        CARTRIDGE, filed Sep. 29, 2012, now U.S. Pat. No. 8,733,613;    -   U.S. patent application Ser. No. 13/036,647, entitled SURGICAL        STAPLING INSTRUMENT, filed Feb. 28, 2011, now U.S. Pat. No.        8,561,870;    -   U.S. patent application Ser. No. 13/118,241, entitled SURGICAL        STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT        ARRANGEMENTS, now U.S. Pat. No. 9,072,535;    -   U.S. patent application Ser. No. 13/524,049, entitled        ARTICULATABLE SURGICAL INSTRUMENT COMPRISING A FIRING DRIVE,        filed on Jun. 15, 2012; now U.S. Pat. No. 9,101,358;    -   U.S. patent application Ser. No. 13/800,025, entitled STAPLE        CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13,        2013, now U.S. Pat. No. 9,345,481;    -   U.S. patent application Ser. No. 13/800,067, entitled STAPLE        CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13,        2013, now U.S. Patent Application Publication No. 2014/0263552;    -   U.S. Patent Application Publication No. 2007/0175955, entitled        SURGICAL CUTTING AND FASTENING INSTRUMENT WITH CLOSURE TRIGGER        LOCKING MECHANISM, filed Jan. 31, 2006; and    -   U.S. Patent Application Publication No. 2010/0264194, entitled        SURGICAL STAPLING INSTRUMENT WITH AN ARTICULATABLE END EFFECTOR,        filed Apr. 22, 2010, now U.S. Pat. No. 8,308,040, are hereby        incorporated by reference herein.

Although various devices have been described herein in connection withcertain embodiments, modifications and variations to those embodimentsmay be implemented. Particular features, structures, or characteristicsmay be combined in any suitable manner in one or more embodiments. Thus,the particular features, structures, or characteristics illustrated ordescribed in connection with one embodiment may be combined in whole orin part, with the features, structures or characteristics of one oremore other embodiments without limitation. Also, where materials aredisclosed for certain components, other materials may be used.Furthermore, according to various embodiments, a single component may bereplaced by multiple components, and multiple components may be replacedby a single component, to perform a given function or functions. Theforegoing description and following claims are intended to cover allsuch modification and variations.

The devices disclosed herein can be designed to be disposed of after asingle use, or they can be designed to be used multiple times. In eithercase, however, a device can be reconditioned for reuse after at leastone use. Reconditioning can include any combination of the stepsincluding, but not limited to, the disassembly of the device, followedby cleaning or replacement of particular pieces of the device, andsubsequent reassembly of the device. In particular, a reconditioningfacility and/or surgical team can disassemble a device and, aftercleaning and/or replacing particular parts of the device, the device canbe reassembled for subsequent use. Those skilled in the art willappreciate that reconditioning of a device can utilize a variety oftechniques for disassembly, cleaning/replacement, and reassembly. Use ofsuch techniques, and the resulting reconditioned device, are all withinthe scope of the present application.

The devices disclosed herein may be processed before surgery. First, anew or used instrument may be obtained and, when necessary, cleaned. Theinstrument may then be sterilized. In one sterilization technique, theinstrument is placed in a closed and sealed container, such as a plasticor TYVEK bag. The container and instrument may then be placed in a fieldof radiation that can penetrate the container, such as gamma radiation,x-rays, and/or high-energy electrons. The radiation may kill bacteria onthe instrument and in the container. The sterilized instrument may thenbe stored in the sterile container. The sealed container may keep theinstrument sterile until it is opened in a medical facility. A devicemay also be sterilized using any other technique known in the art,including but not limited to beta radiation, gamma radiation, ethyleneoxide, plasma peroxide, and/or steam.

While this invention has been described as having exemplary designs, thepresent invention may be further modified within the spirit and scope ofthe disclosure. This application is therefore intended to cover anyvariations, uses, or adaptations of the invention using its generalprinciples.

Any patent, publication, or other disclosure material, in whole or inpart, that is said to be incorporated by reference herein isincorporated herein only to the extent that the incorporated materialsdo not conflict with existing definitions, statements, or otherdisclosure material set forth in this disclosure. As such, and to theextent necessary, the disclosure as explicitly set forth hereinsupersedes any conflicting material incorporated herein by reference.Any material, or portion thereof, that is said to be incorporated byreference herein, but which conflicts with existing definitions,statements, or other disclosure material set forth herein will only beincorporated to the extent that no conflict arises between thatincorporated material and the existing disclosure material.

What is claimed is:
 1. A surgical stapling anvil, comprising: an anvilbody, comprising: a longitudinal slot defining a slot axis, wherein saidlongitudinal slot comprises slot surfaces facing each other; atissue-facing surface, comprising: a first side and a second sidedefined by said longitudinal slot; and a plurality of staple-formingpockets arranged in a plurality of longitudinal rows of staple-formingpockets, wherein said plurality of longitudinal rows of staple-formingpockets comprises an inner-most row of staple-forming pockets closest tosaid longitudinal slot, wherein said inner-most row of staple-formingpockets defines a row axis a first distance from said slot axis and afirst outer boundary axis a second distance from said slot axis which isgreater than said first distance; a first ledge configured to be engagedby a firing member as said firing member moves through a firing stroke;and a second ledge spaced apart from said first ledge; and an anvil capwelded to said anvil body, wherein said anvil cap is configured tocontact said second ledge, and wherein said anvil cap comprises: awelded portion welded to a first surface of said anvil body; and anon-welded portion abutting a second surface of said anvil body, whereinsaid non-welded portion comprises an outer-most non-welded regiondefining a second outer boundary axis positioned a third distance fromsaid slot axis, wherein said third distance is less than said seconddistance.
 2. The surgical stapling anvil of claim 1, wherein said thirddistance is greater than said first distance.
 3. The surgical staplinganvil of claim 1, wherein said third distance is less than said firstdistance.
 4. The surgical stapling anvil of claim 1, wherein said anvilcap further comprises alignment surfaces configured to align said anvilcap to said anvil body for welding.
 5. The surgical stapling anvil ofclaim 4, wherein said tissue-facing surface defines a first plane, andwherein said alignment surfaces define a second plane at leastsubstantially parallel to said first plane.
 6. The surgical staplinganvil of claim 1, wherein said welded portion is flared with respect tosaid non-welded portion.
 7. The surgical stapling anvil of claim 6,wherein said welded portion comprises welded, angular surfacescorresponding to angular surfaces of said anvil body.
 8. The surgicalstapling anvil of claim 1, wherein said anvil cap comprises a Y-shapedcross-section.
 9. A surgical stapling anvil, comprising: an anvil body,comprising: a longitudinal slot defining a slot axis, wherein saidlongitudinal slot comprises slot surfaces facing each other; atissue-facing surface comprising staple-forming pockets arranged inlongitudinal rows, wherein said longitudinal rows of staple-formingpockets comprise a first row of staple-forming pockets closest to saidlongitudinal slot, wherein said first row of staple-forming pocketsdefines a first axis at a first distance from said slot axis and a firstouter boundary axis at a second distance from said slot axis, andwherein said second distance is greater than said first distance; afirst shoulder configured to be engaged by a firing member as saidfiring member moves through a firing stroke; and a second shoulderspaced apart from said first shoulder; and an anvil cap welded to saidanvil body, wherein said anvil cap is configured to rest on said secondshoulder, and wherein said anvil cap comprises: a welded segment weldedto a first surface of said anvil body; and a non-welded segmentinterfacing with a second surface of said anvil body, wherein saidnon-welded segment comprises an outer non-welded region defining asecond outer boundary axis positioned at a third distance from said slotaxis, wherein said third distance is less than said second distance. 10.The surgical stapling anvil of claim 9, wherein said third distance isgreater than said first distance.
 11. The surgical stapling anvil ofclaim 9, wherein said third distance is less than said first distance.12. The surgical stapling anvil of claim 9, wherein said anvil capfurther comprises alignment surfaces configured to align said anvil capto said anvil body for welding.
 13. The surgical stapling anvil of claim12, wherein said tissue-facing surface defines a first plane, andwherein said alignment surfaces define a second plane at leastsubstantially parallel to said first plane.
 14. The surgical staplinganvil of claim 9, wherein said welded segment is flared with respect tosaid non-welded segment.
 15. The surgical stapling anvil of claim 14,wherein said welded segment comprises welded, angular surfacescorresponding to angular surfaces of said anvil body.